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Six Sigma
Enhanced with technical case studies and exercises, this course will provide you with tangible solutions to take away and implement
As a result of the mechanization of human tasks during the past two centuries, we are now strongly dependent upon the reliable, continuous operation of machinery. This is true in the petrochemical, transportation, and refinery, chemical, mining, marine, manufacturing and iron steel industries and when these machines fail, serious economic and human losses can occur. Therefore understanding the exact reasons for machinery failure is necessary to achieve trouble-free operation and minimize expenses.
For industrial machinery, a proper failure study which solves the root causes of the failure is a primary tool for maintaining safe operations at minimum costs. This course will teach you the how and why of machinery failures by utilizing the following teaching tools: Actual failure case histories from industrial environment. Maintenance Strategies and their impact on failures Reliability, Availability , maintainability and safety Video documentaries of major machinery accidents Machinery technical reports with detailed drawing Data Analysis softwares used for Failure Analysis Lean Six Sigma tools , DMAIC , DMADV etc
Additionally, mastering the Lean Six Sigma tools to a competency level of green belt will be taught with certification. failure analysis books and files of past machinery incidents and their analysis will be given in electronic format for you to take away and learn from. The failure analysis methods using advanced Six Sigma tools and techniques taught are comprehensive and apply to every type and size of machinery in all industries. Prevent your machines from failing and your organization from losing money due to downtime and associated direct and indirect maintenance costs!
Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @
www.tun.sg
Benefits of Attending
Attend this specialized technical course and you will learn how to: Assess Why machinery fails in a given mode Perform a Root Cause Failure Analysis Write a professional failure analysis report Identify machinery failure causes from machinery drawings Achieve the confidence required to approach difficult machinery failures Redesign machinery for greater reliability Become a machinery failure analyst through learning by doing Learn Advance Six sigma Analysis tools and its integration with Maintenance Programs
Workshop Activities
There will be some exercises and sharing of case studies throughout this 5 day course. Participants are encouraged to ask as much questions as possible to enable an effective learning experience for them.
Training Material
All participants will receive a set of comprehensive training material.
Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @
www.tun.sg
Course Outline
Day One
Introduction to failure analysis of machinery, History How machines fail, what is a machine failure? Examples Life Cycle of and Equipment, technical analysis Role of Failure Analysis in industrial plants, economicsafety value Gas Turbine and Steam Turbine uncontained failures Failure root causes and failure modes Understanding the multiple roots of machinery failures Discussion on the Industrial failure event from Projects, aircraft Industry
Day Four
Wrong failure analysis: Avoiding false conclusions Using Six sigma Tools in Failure Analysis DMAIC tools and Their application in industrial Failures Define, Measure, Analyze, Improve and control tools for use in Failure Prediction, analysis and prevention and control . Failures of Gear-box , Generator, motors and Transformer etc The perfect failure analysis report, composition Machine component failures: - Bearings - Fasteners - Couplings - Mechanical Seals Rotating Equipment Failures - innovative solution through reliability Improvement - Case studies, Pump failure, Gas turbine failures, Power Plants, Aero Engines - Achieving higher Mean time between failures - Exercise on improvements to design of Rotating Equipment
Day Two
The concept of the weak link in machinery, machine design Understanding machine documents OEM vs Operator Possible failure causes, Explanation of primary vs. secondary failures Comparative analysis as a prime tool in solving failures Conflict of interest in failure analysis Field failure analysis, Design associated failures in machinery Examples from Industry - Gas plant disaster due component failures - Manufacturing errors associated failures - Plant pump coupling failure - Analysis of bulk plant coupling failure - Aircraft Gas turbine Engine failure - Triple Spool Gas Turbine Failure - Mining Equipment Failure - Examples of redesigning equipment based upon failure analysis General discussion and problem solving
Day Five
Reliability in design, programs, monitoring and control, reports Reliability Equations and data understanding, Integrating Six Sigma Tools Six Sigma projects to Improve machine performance, reliability and Failure rate reduction. Bearing upgrades, Rolling element bearing catalogue Shaft design upgrades, Aerodynamic path upgrades in Turbo machinery Case study: Steam turbine failure, Gas turbine High MW Power Plants, Compressor failure axial and centrifugal. Risk assessment for plants, GT, HRSG, Generator, Steam turbine and BOP Replicas for HRSG and components, Boilers Tubing etc Understanding Plant Life extension and Failure Predictions
Day Three
Refineries Equipment Failure examples with analysis Bearing Seizures, Exercises on FMEA, FRCA Failure analysis from the point of view of the laboratory, including case histories Exercise on solutions to conveyor shaft failure Metallurgical failures: Field analysis, Multi-casing centrifugal blower design problems and failures Failures issues in Combined Cycle Power Plants, Thermal Power Plants Failure analyst or problem solver?
Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @
www.tun.sg
T.U.N International 16 Jalan Kilang Timor, Redhill Forum, #03-07 Singapore 159308 Tel: 65 6376 3175 Fax: 65 6271 9029
Machinery Failure analySiS and Prevention with lean Six SigMa green belt certiFication
EVENT cODE: mFaNp
3-7 OcT 2011, KUala lUmpUR, malaySIa 9- 13 OcT 2011, abU DhabI, UaE
regiSter 4 For the Price oF 3 by 22th auguSt 2011 to enjoy 25% diScount!!
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Full payment of course fee to be received by the stipulated date of training, failing which T.U.N INTERNATIONAL will exercise the right to refuse entry to the delegate.
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