LebenTech Training Modules

DAY 1

Module 1 – Introduction to Reliability Concepts

• Key reliability considerations in productive systems
• What is reliability
• Operational reliability
• Reliability Engineering
• Typical manufacturing reliability related measures
• Basic definitions of reliability
• Drivers of reliability
• Need for reliability in manufacturing
• Reliability activities and product life cycle
• Cost benefits of investment in reliability
• Failure definition
• Understanding reliability specifications
• Why items or equipment fails
• Repairable and non-repairable system

Module 2 – Reliability Performance Reporting

• How to setup
• What metrics to track
• Design phase reliability tools
• Manufacturing phase reliability tools

Module 3 – Probability and Statistics for Reliability Application

• Introduction to Probability
• Discrete and continuous distribution
• Methods of estimating failures
• Using Hypothesis Testing to solve reliability problems
• WEIBULL Application and its use in reliability
• Software application for WEIBULL analysis
• Interactive exercise

Module 4 – Productive System Reliability Models

• Models that illustrate basic series reliability
• Application of basic parallel reliability model
• Use of active redundancy to improve reliability
• Identification and application of models designated as standby redundancy
• K-out-of-n configuration application
• Interactive exercise

DAY 2

Module 5 – Equipment Reliability Quantification

• Reliability Block Diagram [RBD] Modeling
• Reliability modeling and analysis of a plant or production system equipment
• Fault Tree Analysis [FTA] for reliability risk assessment
• Success Tree Analysis [STA]
• Quantitative analysis of fault tree
• Interactive exercise

Module 6 – Data Collection & Corrective Action System

• FRACAS application in production operation and as a DCS
• Application of RCFA to improve equipment reliability
• Reliability Trend analysis application for reliability evaluation
• CMMS as a viable option as a data collection system [DCS]

Module 7 – Maintainability & Preventive Maintenance

• Basic concepts and definitions
• Quantifiable measures of maintainability
• Analysis of downtime
• Maintenance concepts and procedures
• How to perform maintainability predictions
• Maintenance strategies
• How to decide on PM schedule
• Reliability under preventative maintenance
• Optimum schedule for preventive maintenance
• Analytical maintenance models

DAY 3

Module 8 – Reliability Analysis of Repairable System

• Patterns of failure
• Methods of analysis
• Selecting the appropriate model
• Mean Cumulative Function
• Non-parametric analysis application
• Renewal
• Non-Homogeneous Poisson Process [NHPP]
• NHPP with power intensity
• Parametric analysis application
• Use of software application to perform analysis
• Interactive exercise

Module 9 – Productive System Equipment Reliability

• Reliability improvement process step
• Overall Equipment Effectiveness [OEE]
• Introduction to PFMEA concepts and applications
• Methods for evaluating reliability growth of equipment in production
• Predict failure from maintenance record using Crow-AMSAA model
• Software application to evaluate multiple production systems
• Interactive exercise

Module 10 – Methods for Evaluating System Availability

• Introduction to Availability
• Availability classifications [Ainh, Aa, Oa]
• Availability concepts and definitions
• Availability of repairable systems
• Determining availability of existing system
• Optimizing productive system availability
• System Availability
• Practical application illustrating cost of Unreliability
• Impact of R&M on operational availability
• Factors that affects availability
• Interactive exercise

DAY 4

Module 11 – Process Reliability

• Overview of Process Reliability Application
• Process reliability definitions
• Weibull application of process reliability
• Process Weibull probability plot
• Identification of reliability losses
• Identification of efficiency and utilization loss
• Factors that leads to increased reliability
• Models for the cost of unreliability

Module 12 – Asset Performance & Reliability

• Introduction to reliability centered maintenance [RCM]
• Candidates for RCM Analysis
• RCM Modeling Process
• Impact of proactive maintenance
• Optimum maintenance policy
• Reduction in Maintenance spending through RCM
• Continuous Improvement Applications
• Maintenance Optimization
• Building blocks for asset performance and reliability

Module 13 – Special Industry Application Examples

• Transit system reliability analysis
• Power system reliability analysis
• Communication system reliability analysis
• Oil Analysis
• Airline Applications
• Network Application
• Warranty Analysis
• Life Data Analysis
  • Cutting Tool
  • Brake Pad