Reliability Engineer Course Cycle

In collaboration with I-Care, this course is aimed at experienced maintenance department members (Reliability Engineer, Support and Methods Engineer, Support and Methods Manager, Maintenance Manager) who wish to sharpen their skills in an industrial world where reliability, a direct route to better productivity, is at the centre of many company policies or issues.

Day 1

• Fundamentals of Reliability (To be able to understand the probabilistic theoretical concepts behind maintenance methods)
• INTRODUCTION:
  • The maintenance function
  • Life cycle costing of an asset
  • The problem of defining a maintenance strategy
• THE CONCEPTS OF OPERATIONAL SAFETY  :
  • Theoretical reminder of probabilities
  • Operational safety or the science of failures
  • Basic concepts of operational safety:
    • 1. Reliability
      • Definitions
      • Survival laws and failure rates
      • Lifetime
      • MTTF
      • Failure laws
    • 2. Maintainability
      • Definitions
      • Instantaneous repair rate
      • Repair time
      • MTTR
      • Maintenance
    • 3. Availability
      • Definition
      • How to improve
      • MTBF
    • 4. Security
      • Definition
      • Risk  management
      • Summary practical exercise
      • Question and answer session

Day 2 and 3

• Reliability engineer's tools (Learn the tools and methods to be used to ensure and improve equipment reliability)
• CONTENT:
  • Introduction: the roles and responsibilities of the reliability engineer;
  • Reminders: reliability based maintenance including theories of reliability, maintainability and availability;
  • Measuring the initial situation via the reliability audit;
  • Priority setting via the criticality study;
  • Introduction to the concept of maintenance planning;
  • Introduction to predictive maintenance;
  • Introduction to various tools: the "as-built" survey, planning, critical spare parts management, chasing irritants via the failure occurrence/recurrence study, obsolescence and obsolescence analysis, cost benefit analysis (CBA) and return on investment (ROI);
  • Performance indicators;
  • Design of equipment and installations according to FOMSI (Reliable, Operable, Maintainable, Safe and Inspectable) including an introduction to FMECA and assistance in writing specifications;
  • The benefits of a CMMS system;
  • Question and answer session.

Day 4

• Reliability project management (To be aware of the constraints and particularities of a reliability project, to be able to organise, structure and follow up a project related to the reliability of new or existing equipment and processes and to finish, to be able to frame and address complex reliability problems, both short and long term).

• Overall budget estimate of the reliability project;
• Monitoring tools :
  • Kick-Off meeting: who, what, how, for when;
  • Management of internal and external resources,
• RACI" matrix,
• Skills and training,
• Costs and efficiency,
  • Monitoring indicators (related to costs, deadlines and quality),
  • Reporting and visual communication,
  • Hand-Over,
• Particularities between a reliability project during the construction phase of a new plant/facility and a project on an existing plant/facility;
• Concrete illustrative example: Creation of a targeted maintenance plan
• Example: Design of a targeted maintenance plan
  • to control costs in a steel company (manufacture of metal profiles);
  • Open exercise based on your needs and inputs;
  • Question and answer session.

Note on the training equipment: The project management software is not imposed, the method remains generic and adaptable to the most common management tools.