Excellence and Reliability in Engineering Practices

Excellence and Reliability in Engineering Practices

Methodology:

• Interactive course including dialogues, group exercises, activities, videos, case studies, and presentations of best practices.

Course Objectives:

By the end of the course, participants will be able to:

• Explain how to achieve excellent performance and utilize the Carcharodon model for excellence.
• Develop reliability programs tailored to individual needs of business strategies, assets, and maintenance.
• Analyze current performance using best metrics.
• Calculate potential cost reductions, both fixed and variable, along with productivity and output improvements, and enhance product quality deliverables through reliability improvements.
• Apply key reliability improvement methodologies and necessary tools to enhance performance and reliability.
• Explain best practices in reliability, including design, operations, and maintenance responsibilities.
• Engage colleagues and consider the human factors necessary to support a high-reliability culture.

Target Audience:

This course is suitable for engineers, maintenance managers, maintenance supervisors, planners, project managers, project engineers, operations managers, transformation managers, operations supervisors, and contractors who want to contribute to performance and reliability.

Program Content:

• Reliability and its significance in the broader business context.
• Introduction to reliability.
• Calculating cost reduction and increased production value.
• The impact of reliability on safety, quality, and team morale.
• Overall Equipment Effectiveness (OEE) as an international model for asset performance measurement.
• Defining maintenance and modern maintenance strategy.
• Identifying reliability loss sources and the role of operations, design, and procurement.
• Contractors, materials, and equipment.
• Reliability pyramid.

Best Practices Sources and Excellence Models:

• Reliability metrics.
• Relationship between performance practices and reliability.
• Best practices.
• Case studies of exemplary methodologies.
• Reliability Excellence Model.
• Building reliability focused on the supply chain.
• Customer-centric approach to reliability.

Developing a Unique Reliability Strategy for the Manufacturing Plant:

• Baseline factory performance.
• Highlighting potential improvement levels.
• Benefit case calculation.
• Focusing on the most valuable priorities for any operations.
• Using Define-Measure-Analyze-Improve-Control (DMAIC) methodology for systematic performance improvement.
• Developing an action plan to improve reliability and extend asset life.

Reliability Improvement Tools:

• Fundamentals of reliability-centered maintenance, total productive maintenance (TPM), and Six Sigma.
• Using root cause analysis to address historical failures.
• Critical analyses to determine reliability priorities.
• Preventing future failures using failure analysis models.
• Design reliability.
• Five-step process (5S) to improve the work environment and identify issues.
• Introduction to Single Minute Exchange of Dies (SMED)/Quick Changeover process.
• When to consider advanced software models.
• Reliability focused on shutdown and restart.