Reliability Engineering Applied to Maintenance Management (REAM)

You will learn how to determine asset’s predominant failure patterns as revealed by failure events’ statistical
analyses. You will also be able to make optimum decisions by choosing the most convenient failure consequence management policy to better reduce risks affecting your organization’s goals.

The hands-on class allows you to apply various types of reliability analyses to real world failure data to identify
proper proactive tasks and their corresponding execution frequencies aimed at making your maintenance
program both operationally and economically successful.

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The class concentrates on the practical teaching of RCM-R® as an optimized process for the formulation of
asset and process failure consequence management policies, which consists of five pillars:

1. Data Integrity
2. RCM according to SAE JA1011
3. Analysis RAM
4. Weibull Analysis
5. Continuous Improvement.

The combination of the RCM method with the other tools that incorporates the RCM-R® facilitates its
application and improves its results.

RCM-R® Basic is the first in a series of courses covering this extensive topic. The class serves as a basis for
those professionals who aspire to become certified analysts, facilitators and instructors in the application of
reliability-centric maintenance according to RCM-R®.

The course uses as a support material the recent publication Reliability Centered Maintenance Reengineered:
Practical Optimization of the RCM Process with RCM-R® by authors Jesús R. Sifonte and James V. Reyes-
Picknell.

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This training is a natural follow-up to behaviour‐based safety implementation and focuses on providing a rigorous understanding of human error, including causes and deficiencies resulting in human error, proven proactive error reduction techniques and methods to improve human performance. We will also be covering the following techniques: 28 Types of Human Errors, 10 Human Error Traps in the Workplace, Crew Turnover, 10 Supervisory Skills to Reduce Human Errors, Skill Based Error Reduction Techniques, Rule Based Error Reduction Techniques and Knowledge Based Error Reduction.

Objectives:

1. Provide attendees with the requisite skills and knowledge necessary to effectively reduce human error in the workplace in a proactive manner
2. Understand the conditions that increase the risk of human error in the workplace.
3. Understand how to implement proactive strategies to reduce the risk of human error
4. Understand human error principles and truths
5. Understand ways to improve human performance
6. Understand how to proactively minimize human error through prevention

Target Audience:

• HSE Professionals
• Maintenance Supervisors
• Reliability Professionals
• Safety Personnel
• Line Supervisors
• Operations Personnel
• Upper & Middle Management

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This training is intended to provide facility personnel the requisite skills and knowledge to eliminate the problems and chronic failures that they are experiencing everyday on the job. It is about the failures-of-the-day that do not injure people, cause regulatory concern or cost a fortune. BFA is designed specifically by field personnel, for the field. It can be thought of as a RCA Lite or 5-Whys Turbo. It is meant to adapt to these on-the-fly conditions and not to get stalled in paralysis-by-analysis!

Objectives:

1. Prioritize failures/problems, separate sporadic, unavoidable events from chronic ones.
2. Identify and accumulate necessary failure/problem information using 5 P’s technique.
3. Formulate hypotheses using RCI’s proven “Logic Tree” approach.
4. Verify
5. Determine the root cause(s) and recommend corrective actions.
6. Obtain rapid ROIs within the range of 600 – 1000% of every dollar invested.

Target Audience:

• Facility personnel
• Field personnel
• Anyone who needs to quickly analyse failures to eliminate chronic failures

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A contrast will be made between the pros and cons of the most common RCA graphical expressions (5-Whys, Fishbone Diagrams, Logic Trees). Attendees will participate in the analysis of a basic case study, which will then be applied to the most common RCA expressions. This will allow attendees to understand why some analytical tools are more comprehensive than others, and when each should be applied. This session will provide the attendee a quality control checklist to use, to evaluate RCA presentations that are given to them.

Objectives:

1. Learn the core principles of the PROACT Investigation Management System
2. Understand the technical pros and cons of the most common RCA graphical tree expressions (5-Whys, Fishbone & Logic Trees)
3. Participate in applying a common, basic case study to the three (3) RCA tree structures described.
4. Learn how to evaluate RCA’s presentations made to them using an RCA QA/QC checklist.
5. Create leading and lagging metrics to measure the effectiveness of their RCA effort
6. Make an RCA business case to determine ROI’s for analyses and the RCA effort

Target Audience:

• Executives
• Upper Management
• Persons who are / will be receiving completed RCA reports from their Engineers / Managers

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The attendees will learn how to physically perform an RCA on any type of failure. They will be taught how to develop recommendations for the resolution of identified causes, write a report detailing the RCA results, present their findings to management and track the progress of the recommendations implemented for failure resolution.

Objectives:

1. Identification of restraining paradigms and how they can prohibit finding the solution(s) to problems
2. Link problems and opportunities to chronic and sporadic events
3. Develop a global contact flow diagram for determining failure modes
4. Identification of techniques used in the preservation of event data using the 5 P’s (Parts, Position, People, Paper and Paradigms)
5. Analyze the undesirable event down to its root levels utilizing the logic tree and hypothesis verification technique
6. Determine the physical, human and latent roots of the undesirable event

Target Audience:

• Safety personnel
• Engineers
• Operational Personnel
• Field personnel
• Management
• Anyone that can be involved in the RCA process

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