An Intensive 5-day Training Course
Advanced Reliability Centered Maintenance
Applying Reliability Centered Maintenance for Effective Risk Management and Enhanced Asset Performance
CLASSROOM DATES
INTRODUCTION
This hands-on EuroMaTech Advanced Reliability Centered Maintenance training course will empower you to apply Reliability Centered Maintenance (RCM) in strict accordance with the SAE JA1011 standard, unlocking the full strategic and financial benefits of this definitive, authoritative process.
The objective of maintenance over the last two decades has radically shifted from a simple 'prevention' approach to a sophisticated, risk-based methodology. This evolution has been driven by several critical factors:
- Increasing system complexity: Components may be highly reliable, but failures at the system level have become far less predictable.
- Continuous process integration: Equipment is increasingly chained together into continuous processes, featuring larger machinery with higher capacities—resulting in exponentially bigger losses when failures occur.
- Lean operations: Leaner processes mean less in-process storage and lower inventory levels, where even short-duration downtime severely impacts output.
- Rising customer expectations: Markets demand higher quality at lower prices in real terms. Organizations that fail to adapt to these escalating demands risk obsolescence.
- Stringent compliance demands: Workers, unions, passengers, consumers, and the public demand uncompromising safety and environmental compliance, making industrial action, lawsuits, and consumer resistance more prevalent.
- Elevated standard of care: Physical asset operators and owners are increasingly held to a rigorous 'standard of care' regarding their physical assets.
Preventing all failures is generally no longer feasible from a technical or economic standpoint. The aviation industry discovered this by the mid-1970s; as modern equipment technology advanced, traditional maintenance strategies fell short. Unfortunately, many organizations today still rely on these outdated, ineffective strategies.
Maintenance strategies must evolve to support the sophisticated technological requirements of modern equipment and the high-stakes challenges of a competitive, highly regulated environment.
Just as financial auditors apply 'due diligence' to an organization's financial assets, maintenance professionals must apply due diligence to physical assets. Similarly, just as the justice system requires 'due process,' physical asset managers must apply due process in their asset management strategies. Unfortunately, many managers still rely on gut feeling. Applying RCM in accordance with SAE JA1011 remains the only credible, globally recognized method for developing robust failure management strategies and tactics for any physical asset.
TRAINING OBJECTIVES
- Apply 'due process' in the context of advanced physical asset management
- Strategically select systems for reliability and risk improvement initiatives.
- Assemble and lead high-performing teams for reliability and risk analysis projects.
- Establish precise boundaries for comprehensive analysis.
- Accurately describe the operating context of complex systems.
- Identify critical functions and define appropriate performance standards.
- Clearly define the failed states of a system.
- Pinpoint reasonably likely failure modes and mechanisms.
- Determine when to utilize a 'black box' approach versus analyzing components separately.
- Analyze the local, intermediate, and end effects of various failure modes.
- Grade failure consequences accurately—by type, severity, and probability—for robust risk assessment.
- Correlate specific failure modes with their failure patterns and probability density curves.
- Determine the effectiveness conditions for various routine maintenance types.
- Identify effective conditions for one-time strategic changes.
- Recognize scenarios where one-time changes are absolutely mandatory.
- Utilize decision diagrams to select the most optimal failure management policy.
- Calculate residual risk to validate policy effectiveness.
- Methodically record the analysis and decision-making processes.
- Prepare comprehensive analysis results for rigorous audit reviews.
- Specify routine maintenance tasks and establish exacting standards for execution.
- Package routine maintenance tasks seamlessly for scheduling and execution.
- Assign routine tasks to the most appropriate roles, including operations personnel.
- Flawlessly implement once-off strategic changes.
- Systematically purge outdated, legacy policies from the organization.
- Embed RCM decisions directly into Computerized Maintenance Management Systems (CMMS).
- Restore optimal operating conditions to maximize the effectiveness of routine maintenance.
- Continuously monitor and review failure management policy effectiveness in perpetuity.
- Leverage Root Cause Analysis (RCA) effectively within the failure management lifecycle.
WHO SHOULD ATTEND?
Delegates are key team members who will drive the development and implementation of reliability and failure management strategies for their organization's physical assets.
Ideal Learners include:
- Maintenance and Reliability Engineers and Engineers in Training
- Engineers Involved in Extensions, Upgrades, Procurement of New Equipment
- OEM Design, Engineers, Field Support Technicians
- Maintenance Supervisors
- Master Craftsmen/Artisans
- Technicians and Inspectors
- Operations Supervisors
- Maintenance Planners
TRAINING METHODOLOGY
Each topic is presented by means of short lectures, discussions followed by intensive practical application using real life case studies. This ensures that learners gain hands-on know-how so that they can participate effectively in risk and reliability projects at the workplace. Learners that gain a high level of competence in this Advanced Reliability Centered Maintenance training course are candidates for further learning and could become risk and reliability management project facilitators.
TRAINING OUTLINE
Day 1: The History and Current State of Maintenance
- The Current Status of Physical Asset Management
- 'Due Diligence' and Physical Asset Management
- What Happens When 'Due Diligence' is Lacking
- Reliability Defined
- Risk Defined
- Where to Start
Plant/Equipment Decomposition
- Functional Locations
- Criticality Grading
- Performance Gap Analysis
- Short List of Systems to Review and Boundary Determination
- Operational Context and Functional Analysis
Define the Operating Context
- Identify Primary, Inherent and Functions
- Determine Desired vs. Designed Performance Expectations
- Practical: Perform Functional Analysis
Failure Analysis
- Failed States
- Failure Events, Failure Modes and the Levels of Causation
- Failure Mechanisms
- Physical Mechanism
- Human Mechanisms
- The Concept of 'Reasonably Likely'
- Failure Effects, Local, Intermediate and End
- Practical: Perform Failure Analysis
Day 2: Risk Management is Integral to Physical Asset Management
Types of Risks
- Operational and Financial
- Safety, Health and Environmental
- Hidden Failure
- Quantification
- Practical: Perform Risk Analysis
Risks Assessment
- Severity/Consequence Assessment
- Probability/Likelihood Assessment
- Grading of Risk
- Develop a Company Specific Risk Grading Matrix
- Practical: Perform Risk Assessment
Day 3: Basic Failure Modes and Mechanisms
- Attrition Inducing Mechanisms
- Fracture Inducing Mechanisms
- Contamination Related Mechanisms
- Disassembly, Misalignment, Chemical Breakdown and Decay
- Temperature, Flow, Pressure, Humidity, Temperature Shock, etc
- Policy Selection Risk Criteria
- Human Factors Including Physiological, Psychological, Anthropometric
- The Six Failure Probability Density Curves
- Age Related and Random Failures
Day 4: Proactive Maintenance Selection Process
Policy Decision Making Diagram
- Policy Decision Making Diagram
- Overall Selection Criteria
- Types of Proactive Maintenance and How to Select Appropriate Intervals
- Function Testing/Failure Finding and How to Determine the Interval
- Instrumented Protective Functions that are Fail-to-Safe
- Types of Condition-Based Maintenance and How to Determine the PF Interval
Policy Decision Diagram
- Potential Failure Characteristics
- Potential Failure Lead Time Estimation
- Types of Condition Monitoring
Optimizing Reliability and Maintainability
- One-Time Changes to Improve Reliability: Physical, Procedural, Human Capability
- One-Time Changes to Improve Maintainability
- Risk Tolerance and Residual Risk
- Determine Residual Risk
- Practical: Select and Define Appropriate Maintenance Policies/Tactics/Strategies
Day 5: Implement Risk and Reliability Management
- Setting Up Risk and Reliability Analysis Projects
- Selection of Team Members
- The Role of the Facilitator
- Selecting and Setting up the Review Projects
- Obstacles to the Process and How to Overcome Them
- Auditing the Decision Making
- Implementing the Results
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ACCREDITATION
EuroMaTech is registered with the National Association of State Boards of Accountancy (NASBA) as a sponsor of continuing professional education on the National Registry of CPE Sponsors. State boards of accountancy have final authority on the acceptance of individual courses for CPE credit. Complaints regarding registered sponsors may be submitted to the National Registry of CPE Sponsors through its website: www.NASBARegistry.org.
Euromatech is a Knowledge & Human Development Authority (KHDA) approved training institute in Dubai, licensed and approved to deliver training courses in the UAE.
The KHDA is the regulatory authority in the UAE, that oversees administering, approving, supervising, and controlling the activities of various education providers in the UAE. We are proud of our commitment to ensuring quality training courses and status as a KHDA-approved training provider.
FAQ
EuroMaTech provides a range of ISO certification and compliance training courses, including:
- ISO 9001 – Quality Management Systems Training
- ISO 45001 – Occupational Health & Safety Management Training
- ISO 14001 – Environmental Management Systems Training
These courses help organizations adopt internationally recognized standards and improve their overall performance.
To register for a training course, you can:
- Visit the EuroMaTech website, browse the available courses, and follow the online registration process.
- Contact EuroMaTech’s support team for assistance with course selection or inquiries about corporate training solutions.
EuroMaTech stands out as a leader in training and professional development due to:
- 30+ years of experience delivering high-impact training courses across industries.
- Accreditations from leading institutions, ensuring top-tier course quality and recognition.
- A portfolio of thousands of training courses, serving professionals at every level.
- A focus on innovation and future-ready learning models, including blended and digital training.
- Long-term partnerships with organizations globally, ensuring sustained success through talent development.
EuroMaTech has successfully delivered thousands of training courses, with thousands of professionals from over 50 countries attending annually.
We are happy to share the profiles of our expert instructors. To learn more about their qualifications and experience, please contact us info@euromatech.com
We provide two flexible training formats to suit your preferences:
- Classroom Training: Experience in-person learning with expert instructors. Engage in interactive discussions, hands-on activities, and benefit from face-to-face networking.
- Online Training: Join live online sessions from anywhere, offering flexibility for those with busy schedules or who prefer remote learning.
- In-House Training: We can bring our training directly to your organization, allowing for tailored sessions that address your specific needs and objectives.
Yes, we provide tailored training solutions designed to meet the specific needs of your organization. Customized courses can be delivered either in-person or online, and you can select the dates and duration that best fit your schedule. For more details, please contact us at inhouse@euromatech.com
Yes, we can assist you with the following:
- Corporate Discount: If available, we can extend our corporate discount for your stay at selected hotels.
- Hotel Suggestions: We can provide recommendations for nearby hotels based on your preferences and budget.
Feel free to explore online booking platforms for the most cost-effective options.
