This course reviews the key concepts and methods in reliability engineering. Using the key concepts and methods, the course examines the effect of different maintenance strategies including scheduled maintenance, preventive maintenance, Total Productive Maintenance (TPM) on manufacturing and elaborates on how system output can be optimized. The advanced system diagnostics techniques of statistical process control, signal diagnostics, decision support systems will be developed through illustrated examples and case studies. These techniques are critical to the success of maintenance strategies implementation. The effect of human reliability, occupation, health and safety issues is also addressed in relation to manufacturing capacity availability.

Upon successful completion of this course, the delegates will be able to:

• Develop your ability in formulating suitable maintenance strategies to achieve reliable a manufacturing system
• Empower the skills to manage a manufacturing system to achieve continuous system availability for production
• Equip with essential system diagnosis techniques to identify and take appropriate actions on error symptoms and causes of failures
• Understand the relationship of key concepts in reliability engineering and application to maintenance strategies in a manufacturing environment
• Establish maintenance strategies according to system characteristics and design transition programs to implement strategies
• Manage the manufacturing organization with highest possible availability

This course is intended for team leaders, supervisors, electrical and mechanical maintenance technicians.

Day 1:

Overview

·         An Overview

Evolution of Concepts and Approaches

·         Maintenance: An Evolutionary Perspective

·         New Technologies for Maintenance

·         Reliability Centered Maintenance

Day 2:

Methods and Techniques

·         Condition-based Maintenance Modeling

·         Maintenance Based on Limited Data

·         Reliability Prediction and Accelerated Testing

·         Preventive Maintenance Models for Complex Systems

·         Artificial Intelligence in Maintenance

Day 3:

Problem Specific Models

·         Maintenance of Repairable Systems

·         Optimal Maintenance of Multi-component Systems: A Review

·         Replacement of Capital Equipment

·         Maintenance and Production: A Review of Planning Models

·         Delay Time Modeling

Day 4:

Management

·         Maintenance Outsourcing

·         Maintenance of Leased Equipment

·         Computerized Maintenance Management Systems

·         Risk Analysis in Maintenance

·         Maintenance Performance Measurement (MPM) System

·         Forecasting for Inventory Management of Service Parts

Day 5:

Applications (Case Studies)

·         Maintenance in the Petrochemical Industry

·         Condition Monitoring of Diesel Engines

·         Benchmarking of the Maintenance Process at Banverket

·         Integrated e-Operations–e-Maintenance: Applications in North Sea Offshore Assets

·         Fault Detection and Identification for Long wall Machinery Using SCADA Data

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session