Reliability is a cornerstone of any maintenance process. Get it right and you can enjoy good safety performance, low running costs and a sustainably high production level at the right quality. Reliable plants are usually safer and cite a higher level of morale. Lose control of reliability and operations become less predictable, more chaotic and much more difficult to control.
This is a highly practical course that includes the latest thinking in reliability improvement, how to gain maximum benefit for minimum effort and how to develop bespoke reliability strategies that will integrate effectively with other campaigns. This will include methods and tools as well as the Carcharodon Model of Excellence to add structure and enable participants to break this complex subject into smaller, more understandable parts.
Reliability is not the responsibility of maintenance alone and outstanding performance can only be achieved with a strategy that includes operations, design, materials and contractors. This course is based upon our Model of Excellence for bringing all these considerations together as one to achieve pace-setter standards.
Course Methodology
This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice and the fundamentals of reliability improvement. Participants will have the opportunity to share with the facilitator and other participant on what works well and not so well for them, as well as work on issues from their own organizations.
Course Objectives
By the end of the course, participants will be able to:
Explain how pace-setters achieve outstanding reliability performance and how to use the Carcharodon Model of Excellence
Develop reliability programs that align with the unique needs of their business, asset and maintenance strategies
Analyze their current performance against best-in-class benchmarks
Calculate potential fixed and variable cost reductions along with productivity, output, and product quality improvements, that can be delivered through reliability improvement
Apply key reliability improvement methodologies and tools to improve reliability performance
Explain to colleagues the fundamentals of best practice in reliability, including the responsibilities of design and operations as well as maintenance
Engage colleagues and consider the human factors required to support a high reliability culture
Target Audience
This course is suitable for reliability engineers, maintenance managers, maintenance supervisors, planners, project managers, project engineers, operations managers, shift managers, operations supervisors and people who are in training for these positions. This course is also designed for contractors who want to contribute to the reliability performance of client assets.
Target Competencies
Reliability analysis
Use of reliability tools
Risk assessment
Continuous improvement
Program management
Course Outline
Reliability and its role in the wider business context
An introduction to reliability
Calculating the value of cost reduction and increased production
The impact of reliability on safety, quality and team morale
Overall Equipment Effectiveness (OEE), an international model for measuring asset performance
A definition of maintenance
The move to asset management and the modern maintenance strategy
Sources of reliability losses and the role of operations, design and procurement
Contractors, materials and equipment
The reliability pyramid
Sources of best practice and models of excellence
Reliability benchmarks
The link between performance and reliability practices
Where to look for best practice
Case studies of pace setter methodologies
A Model of Excellence for reliability
Building a reliability focused supply chain
Customer focused reliability
Building a unique reliability strategy for your plant
Baselining plant performance
How to project the potential level of improvement
Calculating the benefits case
How to focus on the most valuable priorities for any business
Using the Define, Measure, Analyze, Improve and Control (DMAIC) methodology for structured performance improvement
An end to end process for reliability improvement and asset life extension
Reliability improvement tools
Key principles of reliability centered maintenance, Total Productive Maintenance (TPM) and Six Sigma
Using Root Cause Analysis to address historic failures
Criticality analysis to prioritize reliability efforts
Proactively avoiding future failures using Failure Mode Effect Analysis
Reliability by design
The 5S process for improving ergonomics and identifying issues
An introduction to the Single-Minute Exchange of Die (SMED) process for reducing downtime to repair
When to consider advanced software models
Reliability focused shutdowns and turnarounds
Human factors to consider
The impact of human factors on reliability performance