Understanding, Measuring & Improving Reliability

Introduction

Poor reliability has a direct impact on the profitability of a company. If reliability is improved we have increased profit margins, reduced risk of safety and environmental incidents as well high moral and satisfied customers.
Reliability techniques have been around for many years yet they are still slow to be adopted in the process sector. One of the main reasons is the inadequate quality of data recorded in the CMMS.
This workshop emphasises the importance of reliability and the collection of good data to support decision making through the use of many examples and case studies.
We will look at what you can do both with historical data collected in the CMMS system and with process log data.
We will also cover both team based improvement approaches as well as statistical techniques.
Some basic reliability theory will be covered, especially in how to prepare the data for analysis and what you can do with good and not so good data.

What you will learn

As a result of attending this workshop delegates will learn:

  • The importance of reliability and the basic principles of data types
  • How to produce better CMMS feedback reports
  • How to develop failure coding systems
  • How to analyse the data held in the CMMS
  • How to audit the Reliability Management System
  • The many tactics to improve Reliability

Contents

Topic 1  Current Problems with CMMS Systems
Discussion of delegates' current issues
Common issues encountered by the instructor including CMMS set up, and poor use of the CMMS functionality
Costs of unreliability and risks

Topic 2  How to Improve Work Order Feed Back Reporting
We will look at examples of poor quality data collection and present a structured feedback reporting process and stress the importance of clear definitions to ensure consistent determination of KPIs
Failure reporting for critical equipment and bad actors

Topic 3  Data Types and Data Handling Techniques
Data Types – Process data and CMMS data, Complete and Censored data
How to use charts to good effect Pareto, Cumulative Charts, Z Charts, and Probability Charts (normal & Weibull Analysis)
Exercises chart plotting

Topic 4 Understanding and Measuring Reliability
Defining reliability, and how to measure
The bath tub curve and synergy with the human life, early life, random and wear out failures and how to manage. Different patterns of failure including the Weibull parameters
Discuss reliability steady state and time dependent metrics, e.g. MTBF, Safe Life, Optimum Life
Delegates will conduct exercises in Excel and commercial reliability analysis software

Topic 5 Analysing Process Log Data
How to analyse Process data and Event Logs to determine times to failure and time to repair and availability
There are variations in the analysis approach, i.e. whether the data is from the start of its life or not

Topic 6 How to Measure Reliability of LRU
How to conduct reliability analysis of Lowest Repairable Units, in order to improve the LRU

Topic 7   Reliability Growth Analysis
What if we don’t have good data at the failure mode level? All is not lost, we show how
We provide a brief review of reliability growth
Exercises

Topic 8 Overview of Reliability Improvement Techniques

Topic 8a   Root Cause Analysis
Identifying opportunities, overview of reliability improvement techniques (RCM, FMEA, RCA, 6 Step Equipment Improvement Process, FRETT Analysis
Developing corrective actions and determining their effectiveness
Exercises

Topic 8b   Criticality Analysis & RCM & FMEA
Different approaches to criticality analysis including prioritisation
Overview of RCM, FMEA and Reverse RCM approaches
Exercises

Topic 8c   Equipment Management
How to implement a structured 6 step approach to manage problem or critical equipment
Case study and exercise: How pump MTBF was improved from 10 months to 44 months

Topic 8d   Corrective Actions
Summary of tactics to improve reliability by different functions’ responsibilities (operations, maintenance , projects, purchasing)

Topic 9   Reliability & Maintenance in the Design Phase
Stages of a project, tactics to ensure high R&M in the project phase

Topic 10  Determine Reliability & Availability of a System
Introduction to RAM Modelling Series and Parallel System
Hot, Cold and Warm Standby Configurations
What If Analysis, e.g. effect of increased redundancy, mothballing, etc

Topic 11   Degradation Analysis
Introduction to Degradation Analysis, e.g. predicting time to failure based on inspection data

Who Should Attend

Managers, Engineers, Planners, Project and Design Engineers who have an interest in reducing costs and improving plant performance through reliability engineering
A computer is REQUIRED please ensure you have the rights to install new software programmes
Software will be installed for a limited period; this will be a full version.

Training Methodology

Delegates will learn by active participation during the workshop through the many exercises, examples and the use of software
Learning mediums will be PowerPoint presentations, case studies, exercises, software
Applications using MS Excel and specialised software