COURSE OVERVIEW:

The fundamental meaning of this course is the integration of engineering reliability principles with the strategic application of maintenance resources based on calculated risk profiles. Participants will explore the mathematical relationship between failure probability and the resulting consequences to human safety, environmental stability, and production output. The curriculum moves beyond traditional fixed-interval maintenance to a dynamic model where the intensity of asset care is directly proportional to the risk it poses to the organization.

The scope of this training involves a technical deep dive into the "RAM" framework—Reliability, Availability, and Maintainability—and how these metrics influence the design of a Risk-Based Maintenance (RBM) program. Attendees will analyze failure patterns using statistical distributions and learn to calculate the "Risk Priority Number" for complex industrial systems. The course emphasizes the transition from a "one-size-fits-all" maintenance approach to a tailored strategy that optimizes both technical integrity and financial expenditure.

Coverage includes the development of risk matrices, the application of Reliability Block Diagrams (RBD), and the implementation of maintenance task selection logic. The course addresses the human and organizational factors required to sustain an RBM program, including data governance in the CMMS and the management of "Hidden Failures" in protective systems. By the end of this program, participants will be equipped to design and lead a maintenance transformation that balances maximum asset uptime with the lowest possible risk profile.

COURSE OBJECTIVES:

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

• Define the technical interplay between reliability, maintainability, and availability metrics.
• Construct a comprehensive "Risk Matrix" tailored to specific industrial process hazards.
• Analyze failure data using Weibull distributions to identify infant mortality and wear-out.
• Implement a "Risk-Based Maintenance" (RBM) framework for critical process equipment.
• Utilize Reliability Block Diagrams (RBD) to identify system-level single points of failure.
• Calculate the "Total Cost of Risk" to justify proactive maintenance investment to management.
• Master the selection of maintenance tasks based on failure mode and effect consequences.
• Design "Maintainability Standards" to reduce the Mean Time To Repair (MTTR) for critical assets.
• Integrate "Risk-Based" intervals into the Computerized Maintenance Management System (CMMS).
• Manage "Hidden Failures" in emergency shutdown systems and relief valves through testing.
• Conduct a "System Sensitivity Analysis" to identify assets that drive the highest risk.
• Evaluate the effectiveness of the RBM program through "Leading" and "Lagging" indicators.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Maintenance Managers, Asset Management Professionals, Risk Specialists, and Senior Technical Leads.

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.