The foundation of any maintenance process lies in reliability. A well-established reliability framework enables desirable outcomes such as enhanced safety performance, minimized operational costs, sustained high production levels, and consistent product quality. Reliable plants typically exhibit higher safety standards and foster a greater sense of morale among employees. However, when reliability is compromised, operations become less predictable, leading to increased chaos and challenges in maintaining control over the process.

Course Objectives:

By the end of this training course, the 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

Who Should Attend?

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.

Course Outlines:

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 pacesetter 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
Gaining buy-in beyond just the maintenance team
How to get people to own reliability
Developing a reliability culture

Sustaining improvements and tracking performance

The importance of data in performance improvement
Reliability metrics
Use of Pareto analysis
Loss accounting and failure reporting

Reliability roles and organizing for succes

Filters