Reliability Engineering Principles

Reliability Engineering Principles (REP) is a 3-day basic training course for engineers. REP covers the fundamentals of reliability. The course is long on practical problem solving and short on statistical calculations (we use software for the statistics). The course shows how improving reliability boosts business performance by reducing the high cost of unreliability. The reliability tools are used for finding cost issues rather than simply functioning as technical marvels.More than 6000 students from around the world have completed this this training class in the last 20 years with millions of dollars of savings.

Students solve problems during the class to reinforce the lectures (a hand held electronic engineering calculator is required for use by each student). Subjects discussed in the course are generally connected to money issues for finding affordable levels of reliability by use of reliability tools such as (more details on the reliability tools are available):

  • Mean time between failures indices
  • TPM and reliability principles
  • Preparing reliability data for analysis
  • Corrective action for Weibull failure
  • Models & Monte Carlo simulations
  • Pareto distributions for vital problems
  • Fault tree analysis
  • Design review
  • Load/strength interactions
  • Software reliability tools
  • Sudden death and simultaneous testing
  • Reliability growth models and displays
  • Reliability policies and specifications
  • Reliability audits
  • Bathtub curves for modes of failure
  • Effectiveness: availability, reliability, maintainability, and capability
  • Weibull, normal, & log-normal probability plots
  • Decision trees merging reliability and costs
  • Critical items significantly affecting safety/costs
  • Failure mode effect analysis
  • Quality function deployment
  • Mechanical components testing for interactions
  • Electronic device screening and de-rating
  • Reliability testing strategies
  • Accelerated testing
  • Failure recording, analysis, and corrective action
  • Contracting for reliability
  • Management's role in reliability improvements

REP course is 2-3/4 days in length--4 days if English skills need a little sharpening. The REP training course also has a Management Overview requiring 1-1/2 hours for educating managers in the principles studied by their engineers. The agenda for the 2-3/4 day course is:

Day 1--

Introductions and General Information
Setting The Stage For Reliability
Reliability Data Problems and Deficiencies
Computer demonstration of probability plots
Demonstration Project Introduced
Homework-Evening-Problems 1-8

Day 2--

Review of Day 1 Homework
Reliability Models
Computer demonstration of Monte Carlo models
Management Systems For Reliability
Mechanical Components And Systems Reliability
Electronic System Reliability
Demonstration Project Preliminary Commitment
Homework + Self Assessment Audit-Evening-Problems 9+

Day 3--

Review of Day 2 Homework
Software Reliability
Reliability Testing
Reliability Growth Monitoring
Computer demonstration of Crow/AMSAA plots
Reliability Management
Demonstration Project Commitment
Questions, Comments, And Feedback
Seminar Evaluation

Management Overview (if required--1.5 hrs duration)

The class commences at 8:00 AM and ends at 5:00 PM with 45 minutes for lunch. A ten minute break occurs in the morning and one in the afternoon.

Each demonstration project must provide a cost reduction of at least US$4,000 as the minimum goal.

 The REP course usually requires a one additional day of follow-up class concentrating on the demonstration projects. The follow-up class is a coaching effort conducted 6-8 weeks after the 3-day training. The students use the elapsed time for solving practical problems. Coaching is usually required on demonstrations projects selected by the students to show they have mastered the skills of using reliability tools for solving cost problems. This one-day follow-up class concerning the demonstration project is a coaching and tutoring effort to help the students across small problems delaying action on important cost issues.

Who should attend the Reliability Engineering Principles training class?

          Production supervisors will find new tools in reliability engineering principles for understanding how operations can improve reliability of their processes. They will learn how to influence improvements in availability, how they can assist in reducing process failures, and how they can calculate the cost of unreliability for making business decisions to attack problems of unreliability.

         Engineering personnel will find new modeling techniques for predicting equipment reliability based on how equipment is installed, operated, and maintained to assist them in making life cycle cost decisions in justifying new equipment and new processes.

         Maintenance engineers will find reliability tools helpful for providing supporting evidence during root cause analysis failure investigations. They will find reliability tools and techniques helpful for understanding failure data in their CMSS systems, and they will see how to make business decisions, based on the failure data, to justify making equipment more reliable.

†††††††† Reliability engineers who have the job title for style but lack the substance of the analytical details for computations that will improve reliability of equipment and processes.

         Managers will find business aspects of reliability engineering principles helpful for measuring and motivating improvements in processes, procedures, people, and equipment to reduce the cost of unreliability through use of non-traditional tools as they ferret-out hidden factories wasting time and money. They will learn how to predict future failures as a selling point for improvement projects.

The REP class usually precedes the Life Cycle Cost training class to familiarize students with failure rates and failure modes needed for the cost models.Process Reliability training shows how to us the daily output from the production process to quantify special cause losses and common cause losses which together represent the hidden factory.Training in the use of reliability software is emphasized for quickly giving the data a voice for statistical models with the training classes for SuperSMITH Weibull and SuperSMITH Visual software.

Refer to price lists for information about training costs.Check the schedule for available times.Download a copy of a short Reliability Engineering Principles brochure as a (41K) PDF fileóif you need a PDF reader, download the free Adobe software.

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Last revised 06/06/2013