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Course Outline
I - Introduction
to Reliability Engineering & Maintenance
- What is
reliability, why reliability?
-
Reliability concepts
- The
changing world of maintenance
- The
different disciplines involved in
repairable systems analysis
II -
Life Data Analysis
Statistical
Theory Background, and Applications
- Basic
definitions and concepts
- The most
commonly used distributions for product
life and their applications
- 1,
2 and 3-parameter Weibull, mixed Weibull,
1 and 2-parameter exponential, lognormal,
normal
- The most
applicable distribution for your data
- Product
life data types, presented and defined
- Complete
data, right censored/suspended data,
left censored data, interval censored
data, grouped data
- Parameter
estimation methods and theory
- Probability
plotting, rank regression analysis,
maximum likelihood estimation (MLE)
- Confidence
bounds
- Fisher
matrix, likelihood ratio and beta-binomial
bounds
Applying
Life Data Analysis
- Tracking
an item's reliability and guiding corrective
actions through the use of field data
- Predicting
number of returns/failures
- Reliability
specifications
- Optimum
replacement time determination
- Spare
parts determination
- Reliability
goals (specifications), setting and meeting them
- Supplier
reliability issues
- Failure
behavior assessment and failure mode detection
- Warranty
time determination
- Analysis
of different failure modes
- Reliability
bathtub curves
- Comparing
designs, suppliers and data sets
-
Competing failure mode analysis
- Degradation
analysis
- Event
Log analysis
-
Contour plots and their application
- Tests
of Comparison
Weibull++ 7 Software Familiarization
This hands-on
workshop will be based on ReliaSoft's Weibull++
Training Guide. The training guide is specifically
designed to guide you step-by-step from simple
to advanced concepts, allowing you to proceed
at your own pace.
III -
Recurrent Event Data Analysis Approach for
Repairable Systems
- Renewal
process
- The
non-homogeneous Poisson process approach
- Power
law Poisson process
-
Concept of minimal repair
-
Laplace trend test
- Cramér
von Mises test
-
Reliability metrics
-
Expected number of failures
-
Mission reliability
-
Optimum overhaul
-
Failure intensity/
mean-time-between-failures
- General
Renewal Process (GRP) model approach
-
Applications and interpretations of the
model
- Type I
and type II GRP models
- The
effectiveness factor
-
Non-parametric recurrent data analysis
approach
- Mean
Cumulative Function (MCF) and its
application
-
Weibull++ RDA tool and RGA 6 software
familiarization
IV -
Reliability Centered Maintenance (RCM):
Introduction and Overview
-
Introduction and overview
-
History
-
Applications and benefits
-
Published guidelines
- Prepare
for the analysis
- Select
the equipment to be analyzed
-
Published equipment selection questions
-
Criticality factors
- Identify
the functions
- Identify
the functional failures
- Identify
and evaluate (categorize) the effects of
failure
- Identify
the causes of failure (failure modes)
- Select
maintenance tasks
-
Published task selection questions
-
Comparing maintenance strategies based
on cost and availability
-
Run-to-failure
-
Repair/replacement
-
Service tasks
-
Failure-finding inspections
-
On-condition inspections
-
One-time tasks
-
Calculating optimum maintenance interval
- RCM++
software familiarization
V -
Repairable System Analysis with RBDs
System Analysis:
Introduction and Overview
- Defining
a system
- Viewing
a system as a collection of components and/or
component failure modes
Elementary
RBD Constructs and their Analytic Quantification
- Using
RBDs to represent the reliability model
of a system
- Series
configurations
- Simple
parallel configurations
- K-out-of-n
configurations
- Complex
configurations
- Complex
configurations for failure modes, networks
and mechanical systems
- Introduction
to time dependency
- Inclusion
of "used" components in modeling
- System
reliability metrics:
- Obtaining
a system pdf
- Derivation
of functions of interest: system failure
rate function, system MTTF, etc.
Advanced
RBD Constructs and their Analytic Quantification
- Modeling
standby redundancy:
- Energized
and quiescent failure distributions
- "Hot,"
"Warm" and "Cold" standby definitions
- Switching
(perfect or imperfect switching, with
delays, retries and switch quiescent
failure probabilities)
- K-out-of-n-plus-M
standby configurations
- Additional
RBD constructs:
- Nodes
- Containers
- Block
encapsulation (sub-diagram blocks)
- Block
multiplicity
Reliability Importance
- Identify
importance of components and subsystems
(and/or modes) and their overall impact on
system reliability
Fundamentals
of Maintainability and Availability
- Repair
and downtime distributions and metrics
- Introduction
to renewal theory
-
Introduction to maintainability
- Imperfect
repairs (restoration factors)
- Availability
definitions:
- Instantaneous
(point) availability
- Mean
availability
- Steady
state availability
- Inherent
availability
- Achieved
availability
- Operational
availability
Preventive Maintenance (PM) Principles
- When does
"preventive maintenance" make sense?
- The fallacy
of "constant failure rate" and
"preventive replacement"
-
Quantifying preventive vs. corrective replacement strategies
- Determining
optimum PM intervals
- Modeling
effects of PM actions
Advanced
Simulation Options: Using Policies, Pools and
Resources
- Adding
crews to the analysis
- Probabilistic
elements
- Crew
costs
- Crew
utilization metrics and bottlenecks
- Adding
spare part pools (depots) to the analysis
- Probabilistic
elements
- Spare
part inventory management, costs
- Spare
utilization metrics and bottlenecks
- Standard,
on-condition and upon emergency spare
part provisioning with associated costs
and probabilistic delays
- Utilizing
"corrective," "preventive" and "inspection"
actions with associated policies
- Corrective
actions, "immediate" or "upon
inspection"
(hidden/discovery)
- Inspections
based on system time, component age
and/or other system events (e.g.
similar component failure elsewhere
in the system)
- PM
actions based on system time, component
age and/or other system events (e.g.
similar component failure elsewhere
in the system)
Visualizing
and Improving System Availability
- Looking
at common metrics (MTBF, MTBDE, MTBE, AX,
etc.) and charts.
- Additional
(new) metrics for identifying opportunities
in repairable systems:
- RS-FCI
(ReliaSoft's Failure Criticality Index)
- RS-DECI
(ReliaSoft's Downing Event Criticality
Index)
- FRED (Failure
Report Evaluation Diagram) reports
Throughput
Analysis
- Throughput
metrics and terminology
- System
throughput
- Component
throughput
- System
and component utilization metrics
- Bottlenecks
identification
- Backlog
processing
Including
Costs in the Analysis, Introduction to Life
Cycle Cost Analysis
- Determination
of the probabilistic costs associated with
system operation
- Sample
financial analysis
Introduction to Phase Diagrams
RBD vs.
NHPP
-
Advantages and disadvantages of each
approach
BlockSim
7
Software Familiarization
Hands-on
Workshop and Group Case Studies
- Individually
work through detailed examples with step-by-step
instructions to complete sample analyses
that combine many of the concepts
covered in the course.
- Using
realistic cases (described in an objective
statement), determine how to set up and
analyze each case in a team environment.
The case studies combine select topics
covered in the course.
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