COURSE OVERVIEW:

The primary meaning of this course is the systematic removal of the "chronic" small problems that erode plant performance and the mathematical tracking of the resulting reliability improvement. Many organizations are paralyzed by "repeat offenders"—equipment issues that are repaired but never truly solved. This course focuses on "Defect Elimination" (DE) as a grassroots cultural initiative and "Reliability Growth" (RG) as the engineering framework used to prove that the changes are working.

The scope of this training involves the technical application of "Crow-AMSAA" modeling and "Duane Plots" to visualize reliability trends over time. Participants will examine how to build a "Defect Elimination Team" that includes operators, maintainers, and engineers, focusing on the "Top 10" chronic issues that do not meet the threshold for a major RCFA. The curriculum emphasizes the "Design-Execute-Track" cycle, where small engineering changes are made and their impact is quantified through statistical growth analysis.

Coverage includes the identification of "Latent Defects" in the supply chain, the implementation of "Action Tracking" systems, and the management of "Zero-Failure" initiatives. Attendees will explore the specific "Mathematics of Growth," allowing them to predict when an asset will reach its target reliability level. By the end of this course, participants will be able to design a comprehensive program that kills the "Death by a Thousand Cuts" and provides management with clear, visual proof of reliability progress.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the relationship between "Defect Elimination" and "Reliability Growth."
• Master the "Crow-AMSAA" technique for tracking reliability trends.
• Implement a "Defect Elimination" program using a bottom-up approach.
• Identify "Chronic" failures vs. "Sporadic" failures using Pareto analysis.
• Form and facilitate "Action-Oriented" Defect Elimination (DE) teams.
• Utilize "Trend Analysis" to predict future failure frequencies.
• Manage a "Defect Inventory" and track the ROI of small-scale repairs.
• Analyze "Supply Chain" defects and their impact on asset life.
• Utilize "Reliability Growth" models to justify capital investments.
• Differentiate between "Maintenance" and "Improvement" activities.
• Communicate "Reliability Growth" progress to executive stakeholders.

TARGET AUDIENCE:

This course is essential for Reliability Engineers, Maintenance Managers, Performance Analysts, CI Specialists, and Asset Management Professionals.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.