COURSE OVERVIEW:

Rotating equipment, reliability, optimization, and continuous improvement are a high-level strategic course aimed at maximizing the value and performance of industrial machinery throughout its lifecycle. In modern process plants, simply performing routine maintenance is no longer sufficient; organizations must actively seek ways to eliminate defects, enhance efficiency, and extend the intervals between interventions. This course provides the framework for shifting from a traditional maintenance model to a world-class reliability culture where data-driven decisions drive incremental and breakthrough gains in asset availability.

The scope of this course covers advanced reliability methodologies such as Reliability Centered Maintenance (RCM), Failure Modes and Effects Analysis (FMEA), and Life Cycle Costing (LCC). Participants will learn how to analyze equipment history, identify bad actors, and apply the Pareto principle to focus resources where they will have the greatest impact. The Coverage includes the technical aspects of equipment optimization, such as metallurgical upgrades, seal design improvements, and the integration of smart sensors for real-time health monitoring.

Continuous improvement is emphasized through the application of the PDCA (Plan-Do-Check-Act) cycle and the use of Key Performance Indicators (KPIs) to track progress. Attendees will explore how to foster cross-functional collaboration between operations, maintenance, and engineering to solve chronic problems. By the end of this program, participants will be equipped with the tools to reduce the total cost of ownership of rotating equipment while simultaneously improving plant safety and environmental compliance through superior mechanical integrity.

COURSE OBJECTIVES:

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

1. Articulate the principles of World Class Maintenance and Reliability.
2. Calculate and interpret Key Performance Indicators (KPIs) like MTBF and MTTR.
3. Conduct a comprehensive Failure Modes and Effects Analysis (FMEA).
4. Apply Reliability Centered Maintenance (RCM) logic to rotating equipment.
5. Identify and eliminate "Bad Actor" equipment through data-driven analysis.
6. Utilize Life Cycle Costing to justify reliability improvement projects.
7. Implement a "Defect Elimination" program within the maintenance department.
8. Evaluate the impact of operational practices on mechanical reliability.
9. Optimize spare parts strategies to balance cost and availability.
10. Integrate advanced condition monitoring into a proactive maintenance strategy.
11. Design and facilitate Root Cause Analysis (RCA) sessions for major failures.
12. Manage technical changes through a robust Management of Change (MOC) process.
13. Foster a culture of continuous improvement and ownership among the workforce.
14. Benchmark plant reliability performance against global industrial standards.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Maintenance Managers, Asset Integrity Specialists, Plant Engineers, and Operations Leaders focused on long-term performance optimization.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.