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LebenTech Training Modules

Productive Systems Reliability Engineering Applications

Course Code – PSREA 401

Course Overview

This course teaches participants the basic concept of reliability, maintainability and availability methods of application to productive systems. It incorporates the analysis of failure time distribution, the determination of productive system reliability and availability, the cost of unreliability and maintenance schedule optimization. The relationship between reliability, availability and maintenance is also discussed in great details.

Special emphasis is given to methods for analyzing repairable systems data and predicting failures from maintenance data. Quantitative methods for selecting cost effective maintenance intervals are also an integral aspect of this course. The course culminates with methods for evaluating asset performance.


Module 1 – Introdution to Reliability Concepts.

Module 2 – Reliability Performance Reporting.

Module 3 – Probability and Statistics for Reliability Applications.

Module 4 – Productive System Reliability Models.


Module 5 – Equipment Reliability Quantification.

Module 6 – Data Collection and Corrective Action System.

Module 7 – Maintainability and Preventive Maintenance.


Module 08 – Reliability Analysis of Repairable Systems.

Module 09 – Productive Systems Equipment Reliability.

Module 10 – Modules for Evaluating System Availability.


Module 11 – Process Reliability.

Module 12 – Asset Performance and Reliability.

Module 13 – Special Industry Applications.


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


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


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


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

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