Reliability Engineering & Asset Management (REAM) IMechE Accredited CPD Courses

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1 Reliability Engineering & Asset Management (REAM) IMechE Accredited CPD Courses

2 Prof Jyoti Sinha CEng, FIMechE Programme Director, REAM Head Dynamics Laboratory The University of Manchester has been delivering industrially applied professional development courses and consultancy in plant maintenance and reliability for over 20 years. Our teaching style is unique; the courses are explained through industrial case studies and our teaching often takes place at plant sites to demonstrate the real world application of theory. We offer eight IMechE accredited * CPD courses covering the complete spectrum of plant maintenance activities ranging from maintenance design, condition monitoring, maintenance auditing, risk and reliability modelling and turnaround management. The courses are highly recommended for maintenance professionals, engineers and practitioners. The CPD courses are applicable to most industries and service sectors including; Oil & Gas, Nuclear, Railways, Chemical, Food Processing, Energy & Power Generation, Aviation, Manufacturing, Pharmaceuticals, Retail and Leisure. These courses will contribute to your professional development and may be used for obtaining Chartered Engineer Status & Membership. Multiple courses can be combined to achieve a formal postgraduate award. Contact us for further information: Tel: +44 (0) ream.admissions@manchester.ac.uk Direct Taught 5 Day Workshop in Manchester Distance Learning 1 Day Residential or Webinar Interactive E-Learning Platform Discover more about these courses:

3 M01: Asset Management Strategy & Organisation This course is fundamentally about how to develop two crucial strategies (asset management and maintenance strategies) as well as the organisation to implement them in a cost-effective manner. Plant acquisition policy and life cycle costs A methodology for understanding the maintenance function Modelling industrial plant by process flow diagrams Maintenance objectives and decision making Principles of preventive maintenance; definition of a plant item; maintainability diagrams Models for optimising the balance of preventive and corrective work Definitions of operate to failure; fixed time maintenance; condition-based maintenance Selection of the best maintenance procedure in the light of cost, safety factors and how the equipment fails Assembling the maintenance tasks into a complete life plan for a unit or system Producing a balanced forward maintenance plan from all of these unit life plans The top down and bottom up approach to formulating a maintenance strategy Principles behind Reliability Centred Maintenance & Total Productive Maintenance Industrial case studies Assessing the risks from equipment failures Life cycle costing Developing asset strategies from business requirements Linking asset policies & strategies to plans Leadership, communication & culture Continuous improvement Implications of out-sourcing different activities Main types of asset management & maintenance organisations & drivers for them

4 M02: Safety, Legislation & Cost Effectiveness This course aims to discuss the vital parts which safety, legislation & costeffectiveness play in all aspects of maintenance & asset management Management systems for health, safety, environment & quality. Relevant standards & legislation in these areas. Behavioural safety, near miss & accident reporting & investigation. Quantified risk assessments & hazard analysis. Asset integrity management including discussion of risk-based inspection, reliability centred maintenance, equipment in flammable atmospheres, & instrument protective systems. Financial importance of asset management & maintenance including effects on profitability, cash flow & return on investment. Relationship with lean and intangible items. How asset management & maintenance adds value. Making a case for investment or improvement. Costing for maintenance & asset management including lifecycle costing, costing for investments & improvements; dealing with uncertainties & contingencies

5 M03: Asset Maintenance Systems This course aims to: develop understanding of the principles and requirements underlying the concept of system as it is applied to the discipline of Maintenance On completion of this course you should be able to; Demonstrate an understanding of the theory and principles underlying the design, organisation and operation of an effective maintenance system. Generate and justify selection of the most appropriate maintenance processes and options based on plant type, geometric configuration and the operating environment of the equipment Differentiate between the various elements of a maintenance system and integrate the various elements into a complete system. Understand the potential opportunities and threats that may accompany the currently trending fourth industrial revolution through initiatives such as industrial internet of things (IoTs) or e-maintenance or autonomous maintenance or smart maintenance Introduction to the concept of System as applied to Maintenance Critical relationship between systems and organisations Exploring a Model Maintenance system Maintenance Option selection, Planning and Scheduling Processes Issues of controlling the Maintenance management System Maintenance Spares and Logistics Processes Maintenance costing Processes Understand the potential role of maintenance and asset management within the premise of Industry 4.0 Investigate the pros and cons of computerised maintenance management systems and possible improvement opportunities

6 M04: Machinery Vibration-based Condition Monitoring This course aims to give a detailed treatment of the in-situ dynamics characterisation, and detection, possibly location and diagnosis of faults in rotating and reciprocating machinery, using vibration analysis. Introduction to vibration theory to understand machine vibration. Instruments details and their selection guidance to meet the requirements. Vibration measurement procedure including the concept of anti-aliasing and selection of sampling frequency. Signal processing time domain and frequency domain (spectrum, FRF, etc.), filtering, windowing, envelope analysis, phase analysis, order tracking, orbit plot, etc. Theory and laboratory experiments on modal testing, ODS analysis and rotor balancing. Demonstration of a number of industrial case studies linking measurements, data analysis and theory in fault detection & diagnosis, and then solving industrial vibration problems. Use of in-situ vibration tests during machine installation and commissioning, and in solving the vibration problem in the aged machines.

7 M05: Design for Reliability & Asset Management This course aims to present ways in which reliability and maintainability can be taken into account effectively during design. It presents the totality of design activity for the whole product and process life cycle, the control and integration of different technical groups, and shows how and when the process can be influenced to improve maintainability and reliability (M&R). Perspectives of design and design constraints will be discussed in order to identify the most appropriate ways in which design can be improved with respect to M&R. It addresses how design of routines can be improved as an outcome of failures and hence the learning from failures concept. Maintenance awareness and design. M&R background; parameters that can be usefully used in design: MTTR, MTBF, MWT. Learning from Failures. A design perspective and case study based introduction. Design models and evaluation techniques (AHP/ Pugh s Method / QFD). Decision analysis in maintenance and computerised maintenance management systems (CMMSs). Design of maintenance strategy using multiple criteria and resource allocation. The principles of concurrent engineering. Role of marketing, design and manufacturing in concurrent engineering. The process of converting customer requirements to engineering characteristics; the concept of quality function deployment (QFD) and house of quality. Design for X; where X is maintainability, reliability, manufacturability and assembly. Design for manufacturing and design for assembly and concepts and detail. FMEA and FTA in the context of DfR and concurrent engineering.

8 M06: Auditing Asset Management & Maintenance Organisations This course aims to discuss the vital role of Maintenance and Asset Management in supporting the achievement of organisational goals and explain the importance of auditing asset management & maintenance departments. The course describes an overall audit methodology and its associated procedures, models and techniques. Auditing is a practical hands-on process and the skills to be acquired are a mixture of technical and human skills, our course is designed to develop these skills progressively in practice through an actual assessment carried out on an industrial site. Understand the importance of good Analyse data, including information Asset Management and Maintenance to on procedures, identify problem areas the overall bottom line performance of develop solution Asset Intensive businesses Implement effective procedures, Use and customise a methodology techniques and strategies for for auditing an industrial maintenance information gathering function Use spread sheet assessment tool Present an assessment of the results for data collection and performance of an audit and develop action plans for analysis and benchmarking improvement Apply modern concepts of positive Report the results in a structured auditing for performance improvement manner designed to promote Utilise positive interviewing and acceptance of findings communication skills to enhance performance in collecting information

9 M07: Reliability, Maintainability & Risk This course aims to provide a working knowledge of the analytical techniques of reliability engineering, an appreciation of the contribution that these techniques can make to the task of enhancing (a) the effectiveness of the maintenance function and (b) the availability, maintainability and, where relevant, the safety of the physical assets involved and an understanding of the information that will be needed if such benefits are to be realised. Analysing the reliability of plant items: Within the context of Industry 4.0: Setting the scene: needs, definitions, and statistics of item failure. Decision analysis: identifying reliability problems using Pareto and trend analysis. Weibull analysis: graphical analysis of item life data, method of Median Ranks, the Cumulative Hazard plot. Assessing the reliability of plant systems: Reliability Block Diagrams (RDBs): representation and assessment of the reliability of simple configurations. Assessment of larger, more complex and prooftested systems, via System Reduction, Truth Table and Bayesian Techniques. Maintainability analysis. Estimating system repair times. Advanced reliability and safety assessment: Fault Tree Analysis: (a) symbols and construction, (b) minimum cut sets, (c) top event quantification, (d) importance measures. Event Tree Analysis. Simulation. Case studies of applications in design for industrial safety. Human Reliability Assessment (HRA): Overview of Human Factors and methods of Assessment: (a) Alternative methods for HRA, (b) Human Error Assessment and Reduction Technique (HEART), (c) HEART Case studies of applications in industrial safety and production performance.

10 M08: Turnaround Management On completion of this course you should be able to; Generate and justify selection of the most appropriate Turnaround processes and options based on specific Turnaround workscope and the environment within which the Turnaround system must operate. Demonstrate an understanding of the theory and principles underlying the design, organisation and operation of an effective Turnaround Management System. Differentiate between the various elements of a Turnaround Management System and integrate the various elements into a complete Model of Excellence for Turnaround Management. Introduction to the concept of Turnaround Management. The relationship between Business and Event Management. Exploring a Model of Excellence for Turnarounds. Turnaround initiation Planning and Scheduling requirements. Critical elements of the Turnaround model (Organisation, contractors, costs etc.). Executing the Turnaround. Analysing results for continuous improvement.

11 GET IN TOUCH Contact us to find out more: School of Mechanical, Aerospace & Civil Engineering Tel: +44 (0) This brochure is prepared in advance of the entry dates it relates to and all information is accurate at the time of going to press. * Courses M01, M02 & M04 awaiting IMechE accreditation