What does your facility need to focus on to minimize risk and maximize profit? This course focuses in on the practical outcomes reliability engineering should deliver.
This course considers the application of reliability science to best practice in maintenance and process safety. Pre-planned maintenance of process plant was the norm in industry, but with the advent of condition monitoring, expert systems, reliability centered maintenance, Kaizen and total productive maintenance, no plant can afford to be ignorant of the application of the latest approaches.
As well as an overview and practical exercises on reliability and risk, this course provides the knowledge needed to manage assets in a way that minimizes risk, both safety and commercial, to maximize profit.
Who contributes to facility reliability in your organization? Reliability is driven from the top through budgets set for maintenance activities and production targets for facilities, then managed by engineering, reliability, maintenance and operations departments. This course is aimed at leaders, managers, supervisors and engineers who are involved in the processes that deliver a reliable organization.
You Will Learn How to
This course aims to teach in an interesting and new way, to demystify plant reliability, because everybody involved in plant design and safe operation and maintenance needs to understand reliability, not just reliability engineers.
In this course you will learn:
Practical understanding of fundamentals of plant reliability
Common theory required to determine reliability; failure trees, logic and probability, confidence intervals and failure distributions
Reliability modelling, hands on exercises covering how to build reliability block diagrams, populate Monte Carlo models, and run sensitivity cases
An overview of the processes used for managing reliability through plant life, from design and construction, through to operations and end of life
Risk, and commonalities between the calculation of risk that apply to both reliability and process safety
Overall the objective of this course is to provide an understanding of risk and related tools and methods, to allow attendees to manage their assets in a way that minimizes risk, both safety and commercial, to maximize profit.
Reliability Engineering Tools
Reliability Block Diagrams
Failure Modes and Effects Analysis (FMEA)
Monte Carlo Modelling
Reliability Centred Maintenance
Root Cause Analysis
Maintenance Strategy Development
Use of the right tools and philosophy to achieve goals
Risk is made up of two components: consequence and probability. Consequence is much easier to define than probability. Reliability engineering gives us the ability to predict and attempt to control probability, as well as mitigate consequence.
Reliability engineering therefore underpins excellence in maintenance, safety, asset management and operations. As we move into a digital future we have at our disposal a toolset that can be automated to provide the analysis that will drive optimisation.
Why is it then that we don’t use reliability techniques more when defining risk and analysing data? Most people are afraid of the mathematics and modelling that is involved in reliability, but as always, most fear is born out of ignorance. A fundamental understanding of reliability is required whether using traditional techniques or new digital tools; tools will not deliver reliability on their own without this knowledge, but may simply drive a company more quickly in the wrong direction.
Day One of the programme provides an overview of reliability, history and fundamentals including definitions, before looking at reliability calculations. Exercises cover calculation of reliability including Boolean logic, fault trees, distributions, prediction of life through Weibull analysis, and confidence intervals. There is no better way to learn than by doing.
Day Two covers simulations and modelling, with exercises creating reliability block diagrams and Monte Carlo models, before looking at practical application of reliability in design (through determining targets, calculating equipment criticality, setting up ISO14224 equipment boundaries and production reporting), and operations (root cause analysis, defect elimination, FRACAS, benchmarking, logistics and reliability improvement planning).
Before looking at the application of the toolset we must understand the tools and how to use them and this is the purpose of Day’s One and Two of our course.
Day Three we look at various scenarios where we are required to apply our toolset to estimate risk. Each session will revolve around an exercise where we must choose the right approach to the data on hand and perform a rudimentary analysis to accurately predict risk or the ability of the chosen control to mitigate that risk.
Day Four we study maintenance strategy and philosophies, from Six Sigma and Lean, through to ISO 55001. Exercises cover generic maintenance strategies, reliability centred maintenance (RCM), and failure modes and effects analysis (FMEA).
Day Five looks at the application of our tool set to process safety. Process safety deals with more severe consequences than slips, trips and falls. Nor should we make the mistake of attempting to apply reliability techniques to unpredictable events such as human behavior. A safety case is a collection of controls relating to major accident hazards. Using exercises, we will investigate how well controls will function. In the same fashion, we will also look at the factors that cause major incidents and how reliability techniques can be applied to help us predict major accidents.
Upon completion, you will receive a Worley Academy Certificate of Completion