RELIABILITY IMPROVEMENT

Workshop 1 – (2 Days) – Monday & Tuesday, March 12th & 13th

Led by:  Jason Tranter, Mobius Institute

A reliable plant is a safer, more productive, more secure, more environmentally friendly plant,
and its employees are less stressed and more fulfilled! But how do you establish a reliability improvement program? How do you gain support from senior management? How do you change the culture of the organization? There are so many more questions and you need answers if you are going to implement a reliability improvement program.

This highly animated two-day workshop will take you through the entire spectrum of reliability topics, from why the organization will benefit from reliability improvement, through to key implementation issues. This is a detailed workshop that will cover a variety of topics including:

  1. prioritizing the implementation based on business needs and asset criticality,
  2. needs assessments (including the auditing and benchmarking process),
  3. program justification,
  4. asset strategy development (accelerated RCM and FMEA),
  5. breaking out of the reactive maintenance cycle,
  6. work management,
  7. spares management,
  8. precision maintenance (including fastening, alignment, and balancing),
  9. proactive maintenance (including cleaning and lubrication),
  10. condition-based maintenance (including a summary of all of the key condition monitoring technologies),
  11. defect elimination,
  12. root cause failure analysis,
  13. reliability analysis,
  14. operator driven reliability,
  15. continuous improvement, and most importantly
  16. developing the culture of reliability.

This course will provide the education necessary to establish and contribute to a reliability improvement program. It will also prepare you for reliability certification examination.

Detail:

A reliable plant is a safer, more productive, more secure, more environmentally friendly plant,
and its employees are less stressed and more fulfilled! But how do you establish a reliability improvement program? How do you gain support from senior management? How do you change the culture of the organization? There are so many more questions and you need answers if you are going to implement a reliability improvement program. This highly animated workshop will take you through all of the key issues associated with the reliability improvement program. The following list provides a summary of the topics that will be covered.

This is a detailed workshop that will cover a variety of topics including:

  1. The benefits of reliability: we will begin by reviewing the many benefits improving reliability. They include a reduction in safety and environmentally related incidents; improvements in capacity, uptime, and throughput; improvements in quality, and a reduction in costs and waste.
  2. Understanding business requirements: the only reason to improve reliability is to help the business achieve its goals. Therefore we must begin by understanding what those goals are. This is also a necessary step when presenting the business case to senior management.
  3. Quantifying the gap between current performance and targeted performance: using auditing and benchmarking to assess what is the current practice, and measuring the gap to desired practice. This is also a necessary step to justify the program to senior management.
  4. Establishing a master asset list: is not possible to move forward without a detailed master asset list.
  5. Establishing the asset criticality ranking: understanding what the asset criticality ranking is, how it is used, and how to determine the consequence categories, and how to determine the final criticality
  6. Asset strategy development: assessing the root causes of failure and the failure modes to determine how to detect and avoid the root causes, and how to detect and prevent the failure modes – all based on an understanding of the failure patterns and the consequences of failure. The result is an effective condition based maintenance program, preventive maintenance program, the ability to detect hidden failures, and where warranted, a run-to-failure program (This section covers the main tenants of reliability centered maintenance RCM and failure modes effects analysis FMEA.)
  7. Defect elimination: Including designing for reliability, life-cycle-cost-driven procurement, and acceptance testing.
  8. How to break out of the reactive maintenance cycle: a key step if you are ever going to enjoy any success.
  9. Work management: managing the entire process so that all jobs are properly planned and scheduled, with the right people, performing the right tasks, according to defined procedures, using the right spare parts without wasting time or money.
  10. Precision and proactive maintenance: the significant benefits of performing all maintenance tasks, including fastening, shaft alignment, balancing and lubrication with precision, and performing proactive tasks to avoid future failures.
  11. Spares management: ensuring that we have the right parts, in the right volume to minimize overhead costs, and maximize reliability.
  12. Condition monitoring: The strategy and an introduction to all of the key condition monitoring technologies
  13. Root cause failure analysis: FRACAS, the improvement process from identification to verified correction, and the 5-why, Ishikawa and fault tree analysis problem solving processes.
  14. Reliability analysis: A brief introduction to measuring MTBF and Weibull analysis.
  15. Operator driven reliability: Utilizing operators for basic maintenance and CM tasks
  16. Continuous improvement: measuring performance, documenting results, communicating the progress of the program, improving the asset strategies, and more
  17. Developing the culture of reliability: how to break down barriers and gain enthusiastic support for the program, with contributions and participation from all involved.

This course will provide the education necessary to establish and contribute to a reliability improvement program. It will also prepare you for reliability certification examination.