This training course is suitable for a wide range of professionals but will greatly benefit:
Reliability Engineers
Maintenance Engineers
Maintenance Supervisors
Maintenance Planners
Reliability Inspectors
Team Leaders/Managers who are responsible for physical asset reliability and integrity
Duration
5 Days
Programme Overview
This intensive training course aims to equip delegates with skills to the commission, appraise, review and apply risk-based approaches so that organizations can improve the reliability of the assets, reduce maintenance costs and achieve higher levels of safety and environmental integrity over the life cycle of their systems.
Risk management has become the central function of a utility professional and organizations are being held to a higher standard by their shareholders to improve return on investment, by their customers to produce better quality, and by society to improve safety and environmental integrity. Traditional maintenance tactics are unlikely to meet the demands that are placed on the modern organization and for this reason, progressive organization are changing to a risk-based approach.
This training course will feature:
How the objective of maintenance over the last twenty years has steadily shifted from a ‘prevention’ approach to a ‘risk-based' approach
Why the evolution to larger and more complex systems capable of higher capacities leads to greater losses and requires a change in maintenance tactics
How lean processes with less in-process storage and lower product inventories create a bigger demand for reliability
How organizations are being held to a higher standard by society with regard to safety and environmental responsibility
How organizations can overcome the above challenges by applying what they will learn in this course
Objectives
By the end of this training course, participants will be able to:
Choose systems for reliability and risk improvement
Identify functions and appropriate performance standards
Anticipate the failed states, failure modes and damage mechanisms of a system
Apply maintenance tactics to reduce risk and improve reliability
Apply a team-based approach to implement risk and reliability improvement
Methodology
This training course will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension and retention of the information presented. The course will be presented using direct input, discussion and lot of individual and group hands-on practice using real life case studies that will enable the delegates to practice the techniques and processes that they are learning, ensuring maximum knowledge and skill transfer.
Course Outline
Day One: Operational Context and Functional Analysis
Plant/equipment decomposition
Criticality grading
Identify primary, secondary functions
Determine performance standards and quantify
Practical: Perform functional analysis
Day Two: Failure Analysis
Failure modes
The concept of ‘reasonably likely’
Deterioration and damage mechanisms
Physical damage mechanism
Practical: Perform Failure Analysis
Day Three: Failure Effects, Consequences, Probability and Risk
Operational and financial risks
Safety, health and environmental consequences
Hidden failure consequences
Practical: Perform Risk Analysis
The six failure probability density curves
Day Four: Risk-based Maintenance Tactics
Tactic decision diagram
Types of preventive maintenance tactics and how to select appropriate intervals
Types of condition-based maintenance tactics how to determine the PF interval
Function testing and failure finding and how to determine the interval
Practical: Select and define appropriate maintenance tactics
Day Five: Implement Risk-based Reliability Management
