THE COMPLETE GUIDE TO RELIABILITY SKILLS DEVELOPMENT FOR RELIABILITY PROFESSIONALS This guide applies to everyone from graduates, experienced technicians, planners, and engineers, to supervisors, managers and subject matter experts.
THE COMPLETE GUIDE TO RELIABILITY SKILLS DEVELOPMENT FOR RELIABILITY PROFESSIONALS This guide applies to everyone who from graduates, experienced technicians, planners, and engineers, to supervisors, managers and subject matter experts.
RELIABILITY SKILLS DEVELOPMENT
EXPERT REL501 SYSTEM ENGINEERING TOOLBOX & SPECIAL ANALYSES
INNOCENCE REL101 HOW RELIABILITY METHODS IMPROVE ASSET MANAGEMENT Start by gaining awareness of these tools:
Let’s dig in and refine your expertise: • What is Reliability Analysis • Project phases • Design for Reliability • Understanding HAZOP and VAA • System Engineer • Design Related Analytical Tools • Prognostic • Asset Health / System Health
• Reliability Centered Maintenance (RCM) • FMEA / FMECA Maintenance / RPN Analysis • Fault Tree Analysis • Reliability Block Diagrams (RBD) • Failure Data
SO WHAT’S THE END GOAL? To educate and equip yourself to facilitate effective investigations so you can reduce risk and maximize the reliability and availability of your designs, assets or products.
AWARENESS REL201 UNDERSTANDING RELIABILITY ANALYSIS TOOLS Next, you’ll want to understand how to:
AND AFTER ALL, YOU GOTTA HAVE GREAT SKILLS. Here’s a snapshot of the learning curve
• Corporate Risk Matrix / Severity • Integrated Asset Management • Optimized Risk v Cost • Design FMEA • Fault Tolerance • Reliability Modeling
UNDERSTANDING REL301 INTENSE ANALYSIS TOOL SET TRAINING Now it’s time to hone your skills in Reliability including:
NOW LET’S DIVE IN
• Fault Tree Analysis • Introduction to RWB • Advanced Fault Tree Methods • Probability Set Theory • System Qualification • Importance Analyses • Confidence Analyses • Event Tree Analyses
COMPETENCE REL401 UNDERSTANDING ADVANCED RWB CAPABILITIES You’re ready to learn the intricacies of facilitation: • IEC61508 FMEA / SIL Analysis • Quantitative Risk analysis using Fault Trees and Event Trees • RBD with various Failure Models • Advanced RBD Methods • Markov Analysis • Using Parts Libraries • Using Weibull Failure Data
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At this stage, you should be able to: • Design 4 Reliability • Probabilistic Reliability Analysis • Fault Tree & Event Tree Analysis • Calculate System & Subsystem Reliability • Use Parts Libraries • Use Failure Data • Understand HAZOP & VAA
AHHH... IF ONLY THEY COULD SEE ME NOW Focus on developing your Reliability skills as outlined above and you’ll really be ready to flex your Problem Solving muscles.
TO START YOUR JOURNEY, VISIT www.armsreliabilitytraining.com
THE RELIABILITY JOURNEY
BUILDING BLOCKS INNOCENCE AWARENESS
101
REL
Introduction to Reliability Engineering
vv
201
COMPETENCE
EXPERT
301
401
501
Reliability Tools Reliability Analysis Full suite of Reliability Methods -
1 Day Introduction to 2 Day [RWB Reliability Fault Tree [No Software] AWB AVSim]
Foundation Elements
UNDERSTANDING
Reliability Basics
Fault Tree Analysis Event Tree Analysis 2 Day [RWB FT, ET, others]
Core Elements
Advanced Reliability Workbench (RWB) 2 Day [FT ET Markov, FMEA, FMECA, IEC61508, SIL, RBD]
Applying Reliability
System Engineering Tool Box 2 Day Engineering Topics [RWB AWB]
Institutionalizing Reliability
The ARMS Reliability Training Curve aligns to the professionals learning journey to be a Reliability Expert. To learn more, visit our website www.armsreliabilitytraining.com
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REL 101
Introduction to Reliability Engineering Learn about the wide array of reliability tools available to the reliability engineer. The role of reliability engineer requires the engineer to be capable of using a variety of analysis methods to predict and improve reliability of equipment and systems in order to improve design, maintain and operate equipment safely and to meet its intended purpose. In this introductory course we explore a wide array of tools that enable the engineer to become proficient in the role of a reliability engineer. The student will learn the difference between Process FMEA, Design FMEA, RCM FMEA as well as the various scales usually employed to calculate the Risk Priority Number (RPN), and criticality. We will introduce Fault Tree Analysis and Reliability Block Diagrams, Failure Reporting and corrective Action Systems (FRACAS), including the use of work order failure data, Weibull analysis and selecting maintenance tasks using Reliability Centered Maintenance.
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BUILDING BLOCKS
REL 101
Course Overview
A 1 day introduction to over 10 essential Reliability tool sets and methods. A perfect primer for a broad array of reliability training. A perfect introduction for the new graduate engineer or reliability engineer. A great overview for managers and those interacting with reliability.
Course Key Learning The student will be exposed to and work with a variety of reliability methods in a short introduction course using practical exercises to emphasize key elements. Topics include FMEA, Weibull, Failure Data, Reliability Block Diagrams, Fault Tree Analysis and RCM.
Course Modules
Who Should Attend?
• Reliability Centered Maintenance Intro (RCM) • Failure Modes and Effects Analysis (FMEA) • Process FMEA • Design FMEA • Maintenance FMEA • FMECA & Risk Priority Number (RPN) • Cost vs. Risk Ratio Calculations • Failure Data Introduction • Failure reporting Systems • Introduction to Weibull Analysis using failure data • Fault Tree Analysis Introduction • Reliability Block Diagrams (RBD)
• • • • • • • • • • •
Industries • • • • • • • •
Oil and Gas Mining Steel Transport Energy Manufacturing Plant Repetitive Manufacturing Food and Beverage
Engineers NEW Engineers Project Engineers Asset Managers Maintenance Engineers Design Engineers Reliability Engineers/Technicians Operators Safety Engineers Risk Engineers Defect Elimination Managers
Course Information • • • •
Time: 8 Hours (1 day) Exam fee: Included Course type: In House Certification: n/a
INNOCENCE HOW RELIABILITY METHODS IMPROVE ASSET MANAGEMENT Start by gaining awareness of these tools: • Reliability Centered Maintenance (RCM) • FMEA / FMECA Maintenance / RPN Analysis • Fault Tree Analysis • Reliability Block Diagrams (RBD) • Failure Data
www.armsreliabilitytraining.com
REL 201 Reliability Tools
A hands on course covering basic reliability methods using leading software to support real world calculations every reliability engineer must be able to perform. This course builds on the introduction provided in REL 101. The Corporate Risk Matrix is examined, and utilized to calculate Severity and risk thresholds to enable decisions regarding acceptable risk. The Total Integrated Asset management approach (TIAM) is examined to understand how all the reliability tools flow together to produce a total asset reliability system. Monte Carlo Simulations for Cost vs. Risk Optimization are explored using instructor led software exercises. After a brief review of Reliability and probability theory, we launch into the essential elements of Design 4 Reliability (D4R), safety calculations and Safety Integrity Level Calculations (SIL). The D4R considerations flow into the RAMS study requirements (Reliability Availability, Maintainability and Safety) Fault tolerance, redundancy calculations are explored with exercises to support the learning ahead of a deeper review of the Design FMEA using Reliability WorkbenchTM (RWB) Interacting with basic aAvailability and Maintainability requirements. The course covers a full range of Reliability exercises with hands on use of (RWB) to process real world design with basic reliability modeling. * Isograph is the author and legal owner of Reliability WorkbenchTM reliability software.
www.armsreliabilitytraining.com
BUILDING BLOCKS
REL 201
Course Overview Course Key Learning
The course introduces the Reliability tool set beginning with the incorporation of the risk matrix, severity calculations and ISO risk surfaces. The early phases of TIAM are explored with instructor led exercises to reinforce the development requirements of any asset or product. Probabilistic Design using a Design FMEA with portioning, and risk elements allows the reliability engineer to develop real world scenarios for a variety of reliability modeling requirements.
Course Modules
• Risk Matrix, Severity, ISO risk surfaces • Reliability and Availability • Integrated Asset management – Design 4 Reliability – data flows • Cost vs benefit – risk optimization • Reliability theory Review • Probabilistic Reliability Calculations • Safety and SIL calculations • Fault tolerance • RAMS study reliability element introduction • Basic Reliability modeling using Probabilistic methods
Industries • • • • • • • • •
Oil and Gas Electronics Design Aviation Automotive Energy Manufacturing Plant Repetitive Manufacturing System Design Safety Related Products
Who Should Attend? • • • • • • • • • •
Engineers Project Engineers Maintenance Analysts Maintenance Designers Engineers Safety Representatives Operators Administrators Maintenance trades Graduates
Course Information • • • •
Time: 16 Hours (2 days) Exam fee: Included Course type: In House Certification: n/a
AWARENESS UNDERSTANDING RELIABILITY ANALYSIS TOOLS Next, you’ll want to understand how to: • Corporate Risk Matrix / Severity • Integrated Asset Management • Optimized Risk v Cost • Design FMEA • Fault Tolerance • Reliability Modeling
www.armsreliabilitytraining.com
REL 301
UsingReliability WorkbenchTM (RWB) & Fault Tree Analysis Quantify and Mitigate Risk The course provides an in depth review of leading software Isograph’s Reliability WorkbenchTM and how it can be used to determine risk exposure and mitigate that risk. The student will learn the reliability concepts using hands on instructor led exercises designed to empower the student to use these methods in the work place. The course begins with a strong focus on practical Fault Tree Analysis (FTA) using RWBTM Fault Tree Module. Exercises like simple cooling system fault trees introduce the methods of cut sheets, Boolean logic, and simplification methods to reduce Boolean sets. After a review of probability set theory, the addition law, we embark on system qualification theory, TOP sets, System unreliability calculations. Importance analysis is emphasized with a reactor vessel practical example. Initiating events and enablers, along with use of the DLL (Dynamic Link Library) which allow other programs to interact with RWB. Common cause failures, confidence analysis, statistical confidence and Monte Carlo simulation methods are introduced with a series of instructor led examples working within the software to realize models of common systems. Finally the Fault Tree to Event Tree transformation is explored with a series of Event tree Exercises to solidify the total learning process on risk determination and improving safety.
* Isograph is the author and legal owner of Reliability WorkbenchTM reliability software.
www.armsreliabilitytraining.com
BUILDING BLOCKS
REL 301
Course Overview
A perfect hands on course using Fault Tree and Event Tree Analysis methods with Isograph’s Reliability WorkbenchTM software supporting needed calculations. Instructor led detailed exercises ensure full use and comprehension of each topic.
Course Key Learning Reliability Work BenchTM Fault Tree and Event Tree Software are utilized to teach the student the ability to analyse and predict the unreliability and risk exposure of any system or product. The advanced use of Fault Tree enables the student to learn how to use cut sheets, Boolean Logic, and probability and set theory to create a reliability model for any system or product. Working through several instructor led exercises allows the student to confidently navigate the software using the concepts to produce new analysis and predict reliability, number of expected failures, System Unreliability and the risk level for critical safety systems.
Course Modules
Who Should Attend?
• Overview of RWB Fault Tree Module with differences explained • Modeling with Fault Tree • Practical Modeling Methods, Cut Sets, Boolean Logic • Importance Analysis, initiating events • Event Tree Analysis
• Safety Engineers • Risk Specialists • 6 Sigma Black Belts • Maintenance Engineers • Process Engineers • Design Engineers • Operators • Engineers • Instrument/Electrical Engineers • Plant InspectorsProject Engineers • Graduates
TM
Industries • Oil and Gas • Mining • Transport • Automotive • Energy • Manufacturing Plant • Repetitive Manufacturing • Utilities
Course Information
UNDERSTANDING INTENSE ANALYSIS TOOL SET TRAINING Now it’s time to hone your skills in Reliability including: • Fault Tree Analysis • Introduction to RWB • Advanced Fault Tree Methods • Probability Set Theory • System Qualification • Importance Analyses • Confidence Analyses • Event Tree Analyses
• Time: 16 Hours (2 days) • Exam fee: Included • Course type: In House • Certification: n/a www.armsreliabilitytraining.com
REL 401
Design Reliability Methods and Tools SIL, IEC 61508 FMEA, Reliability Block Diagrams, Markov Analysis, Advanced Weibull analysis This course explores several important reliability topics including the IEC 61508 Safety Integrity level Calculations needed to complete a SIL related FMEA using Reliability Work BenchTM (RWB) as a tool to facilitate the learning process. Within the IEC 61508 FMEA learn how to consider reliability allocation, beta values, dangerous failure coverage apportionment. With Direct calculated Reliability Block Diagrams (not Monte Carlo Simulated) learn how to model any complex system or sub system and determine if it meets the design requirements for reliability. Explore various sources of failure model data, library functions and the conversion of RBD to Fault Tree or Event Tree Analysis. These include sources like Markov Models, Weibull data, and other probabilistic model data sources. Instructor led examples walk the student through Markov Analysis & complex modeling, showcasing the extensive capabilities with parts libraries allow the user to predict unavailability using RWBTM models. Weibull failure data is also incorporated into the quantitative models (direct calculation of reliability not Monte Carlo Simulated) * Isograph is the author and legal owner of Reliability WorkbenchTM reliability software.
www.armsreliabilitytraining.com
BUILDING BLOCKS
REL 401
Course Overview
The complete course for demanding reliability application and calculations. Course Key Learning IEC 61508, & SIL FMEA methods needed to produce a SIL compliant FMEA for certification consideration. The use of probabilistic Reliability calculations in place of Monte Carlo Simulations allows the use to calculate precise values for a variety of reliability needs. Reliability Block Diagrams, Fault tree and Event tree Conversions precede the learning that enables the student to develop and calculate Markov Models, and use those Markov models as failure sources for more complex systems
Course Modules
• RWBTM Overview • FMEA/FMECA IEC 61508 • SIL • Direct Calculated Reliability Block Diagrams (RBD) • Advanced RBD Methods – Overhauls, test intervals, conversions to Fault tree and Event Tree Analysis formats. • Markov analysis – constructing models, defining phase transitions, base rates, time dependent rates, • Library functions – Parts libraries • Using failure data – Weibull Failure models.
Industries • Oil and Gas • Electronics Design • Communications • Automotive • Aero Space Engineering • Military
• Chemical Industry • Transport • Energy • Manufacturing Plant • Repetitive Manufacturing • Food and Beverage
Who Should Attend? • Safety Engineers • Designers Engineers • Engineers • Project Engineers • Risk Specialists • 6 Sigma Black Belts • Maintenance Strategists • Protection Engineers • Plant Inspectors
Course Information
COMPETENCE UNDERSTANDING ADVANCED RWB CAPABILITIES You’re ready to learn the intricacies of facilitation: • IEC61508 FMEA / SIL Analysis • Quantitative Risk analysis using Fault Trees and Event Trees • RBD with various Failure Models • Advanced RBD Methods • Markov Analysis • Using Parts Libraries • Using Weibull Failure Data
• Time: 16 Hours (2 days) • Exam fee: Included • Course type: In House • Certification: n/a www.armsreliabilitytraining.com
REL 501
System Engineering Toolbox & Special Analysis HAZOP, Vulnerability Assessment, System Engineering Tools This course builds on the foundation elements of the Reliability program and provides the Engineer a suite of tools and methods they can deploy to monitor and improve plant reliability. The Hazards Analysis & Operability Study (HAZOP) Methodology is explored before launching into the Vulnerability Assessment & Analysis Process. (VAA) These concepts are used to expose special considerations around Human factors, and layers of protection while evaluation the realistic probability of failure, providing both the HAZOP process and VAA process REAL data to base decisions. The HAZOP exercise works a simple reactor and its surrounding equipment using methods learned in REL 301 and 401 to support hazard risk analysis by direct calculation using simple models. The system engineering Tool Box rounds out the suite of tools providing the engineer a wide platform of tools to analyse and report findings.
www.armsreliabilitytraining.com
BUILDING BLOCKS
REL 501
Course Overview
The Special Analysis tools every Engineer should have Course Key Learning • The engineer learns how to interact the learning’s form REL 301 and REL 401 with other study methodologies including HAZOP and VAA. • After major accidents it has been found that gaps in the HAZOP occurred allowing the major accident to occur because a qualitative judgment was substituted for a functional risk calculation. • The Systems Engineering toolbox supplies another level of capability that builds on prior content delivery in the series to add to the reliability engineer’s capabilities to add value by improving reliability, reducing risk and maximizing value.
Course Modules
Who Should Attend?
• Reliability Review • HAZOP Method Overview • HAZOP Exercise using RBD & FT • Vulnerability Assessment & Analysis • System Engineering tool Box • Graphical Presentation and Communication tools • Prognostics Health Management Overview (PHM)
• Engineers • Project Engineers • Risk Specialists • 6 Sigma Black Belts • Maintenance Strategists • Plant Inspectors • Design Engineers • Safety Representatives • Process Engineers • Operators • Graduates
Industries • Oil and Gas • Mining • Utilities • Automotive • Energy • Manufacturing Plant • Chemical Industry • Transport
Course Information • Time: 16 Hours (2 days) • Exam fee: Included • Course type: In House • Certification: n/a
EXPERT SYSTEM ENGINEERING TOOLBOX & SPECIAL ANALYSES Let’s dig in and refine your expertise: • What is Reliability Analysis • Project phases • Design for Reliability • Understanding HAZOP and VAA • System Engineer • Design Related Analytical Tools • Prognostic • Asset Health / System Health
www.armsreliabilitytraining.com
WHO WE WORK WITH
www.armsreliabilitytraining.com
Since 1995, ARMS Reliability has been at the forefront of proactive asset management strategies for a range of blue chip companies throughout the world. These companies have entrusted ARMS Reliability with delivering business goals through effective asset management and improvements in operating productivity. The a unique blend of consulting, education and software solutions, we provide a “one stop shop” service to enable our clients to make better decisions to improve Asset Reliability.
Call to book your course today. Ask our Expert trainers to build your team a customized training career path to Expert! Note: Availability Workbench, AWB, AvSim, RCMCost, Reliability Workbench, RWB are trademarks owned by Isograph and for which ARMS Reliability are authorised resellers.
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www.armsreliabilitytraining.com
NORTH / CENTRAL / LATIN AMERICA P: +1 512 795 5291 AUSTRALIA / ASIA / NEW ZEALAND P: +61 3 5255 5357 EUROPE P: +44 122 445 9362 SOUTH AFRICA P: +27 10 500 8232 www.armsreliabilitytraining.com
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