ARP Category II – Reliability Engineer
Asset Reliability Practitioner Training & Certi cation
The Asset Reliability Practitioner [ARP] Category II “RELIABILITY ENGINEER CORE EDUCATION” course is intended
for industrial reliability engineers charged with helping the organization improve reliability and performance, and
for anyone else in the organization who desires to have an in depth
improvement process.
Detailed topic list:
INTRODUCTION
 Goals of the course
 Goals of reliability improvement
 How reliability/performance improvement is
aligned with asset management, operational
excellence, TPM, and lean
o An introduction to ISO 55000
 The role of the reliability engineer
o Making improvements
o Providing data and recommendations
o Supporting the Category III Program
Leader
STRATEGY AND IMPLEMENTATION
 Bene ts of reliability and performance
improvement
o Aligning the program to meet the
business goals
 The need for the business case
o How to provide data to support the
business case
 How to assist in the development of the “roadmap”
plan
o What are the “essential elements” of a
holistic approach
o How do you break out of the reactive
maintenance cycle
 Understanding the maintenance strategies
o Reactive maintenance
o Strategic maintenance in summary
• Run -to-fail
• Condition - based maintenance
[CBM]
• Interval -based (preventive)
maintenance
• Hidden -failure nding tasks
CAT -II
- knowledge of the reliability and performance
PEOPLE MANAGEMENT
 Culture change
 Helping to gain and retain senior management
support
 Engaging people in the reliability and performance
improvement e ort
o Training and certi ation
o Skills development
o Awareness sessions
 Human error and psychology
o Why errors are made
o Why knowledge and observations about
failure may be awed
 Steering committee
o The role of the RE with the steering
committee
DEFECT ELIMINATION
 Overview
 Design for reliability
 Procurement for the lowest lifecycle costs
 Transportation for minimal degradation
 Managing outside contractors
 Managing vendors
 Acceptance testing
 Work management - introduction
 Spares management/caring for spares
 Precision and proactive maintenance – introduction
 Precision operation and operator driven reliability
[ODR]
RELIABILITY ENGINEERING
 Reliability fundamentals
 Understanding equipment “failure patterns”
o Does all equipment wear out with age?
o What are “random failures”
o Early age “infant mortality” failures
o Nolan and Heap and other studies
o Understanding failure modes
 Page 2 of 4

RELIABILITY ENGINEERING cont’d  How the process may be used in asset

o Understanding failure consequences strategy develop
o Understanding hidden -failures  The overlap between FMECA and RCM
o Collecting failure data to aid PMO, RCM,  Utilizing Reliability Centered Maintenance [RCM]
FMECA, Pareto analysis and RBDs  What is “classic” RCM
 Develop meaningful, useful,  Understanding the seven key elements of
useable failure codes the RCM process according to SAE JA1011
o Determining the reliability of an item  How to prioritiz e the RCM process
 Strengths and weakness of  The logical process to establish the mix of
MTBF the following outcomes on each asset
o The basic principles and pros/cons of CM  Run -to-fail [RTF]
and CBM  Condition -Based Maintenance
o The basic principles and pros/cons of [CBM]
interval -based (preventi ve) maintenance  Interval -based Maintenance
 Analyzing reliability data [IBM] or Preventive Maintenance
o Weibull and other analysis techniques [PM]
 Reliability block diagrams [RBD]  Hidden -failure nding task
o An introduction to constructing RBDs [HFFT]
o Estimating system reliability and  Redesi gn for improved reliability
availability based on RBDs or performance
 Lifecycle cost analysis [LCCA]  Utilizing Pareto analysis
o The principle of lifecycle costs versus  What is Pareto analysis
purchase price  How to collect accurate, reliable failure
o An introduction to LCAA data
 Analyzing the data
ASSET STRATEGY DEVELOPMENT  Utilizing Pareto analysis to prioritize
 Getting the house in order maintenance and reliability decisions
 Developing the master asset list [MAL] aka
asset register [AR] WORK AND SPARES MANAGEMENT
 Utilizing ISO 14224 to de ne the  An overview of work management and spares
hierarchy management and how they are connected
 Developing the Bill of Materials [BOM]  How they relate to preventive work,
 The importance of having an condition -based work, work requests, and
accurate BOM break -in work
 Developing an asset criticality ranking [ACR]  How they relate to
 The importance of having an ACR shutdowns/turnarounds/outages
 Understanding criticality  The bene ts of work and spares
 A methodology to develop the ACR management and key benchmarks
 Prioritizing maintenance, reliability, and  Key components
other decisions based on criticality  Handling maintenance requests
 Utilizing Preventive Maintenance Optimization via observations and CM
[PMO]  Spares management
 What is PMO  Managing preventive tasks (PMs,
 Assessing existing PMs and either keep CM tasks, proactive tasks)
them, improve them, or remove them  Scheduling
 The strengths and weakness of PMO  Managing break - in work
 Utilizing Failure Modes, E ects and Criticality  Reporting, and KPIs to collect and trend
Analysis [FMECA]  Ensuring there is feedback for continuous
improvement

MOBIUS INSTITUTE
AUSTRALIA – BELGIUM – COSTA RICA – UNITED STATES
and authorized training centers in 50 countries
CONTACT: learn@ mobiusinstitute.com
www.mobiusinstitute.com
© 2018 – Mobius Institute – All rights reserved.
 Page 3 of 4

WORK AND SPARES MANAGEMENT cont’d  The importance of developing and

 MRO spares and material management following written procedures
 The consequences of a poor MRO spares  The importance of precision installation in
management components such as bearings (rolling
 Spares policy identi cation element and journal/sleeve), seals, gears,
 The de nition of a “critical spare” belts, pumps, electrical equipment, and
 Spares sourcing other equipment
 Inventory control  Understand the key operating principles
 Spares issuance of rolling element and journal bearings,
 Documentation and analysis seals, gears, pumps, fans, transformers,
 Maintenance planning steam traps, and valves
 Creating a job plan  Understand how to verify electrical
 Allocating people to work systems: fault current, earth loop,
 Determining time, tools, skills, equipment, impedance, insulation resistance, and
and safety requirements protection testing
 Job kitting  Understand the issues related to power
 Maintenance scheduling quality: earth loops, power factor,
 How to prioritize jobs harmonics, EN60130
 Coordinating with production  Understand mechanical and acoustic resonance
 Managing break -in work and the basic correction techniques
 Shutdowns, turnarounds, and outages  Proactive maintenance
 Scope, time, quality, communications,  The importance of taking proactive steps
human resources (site and contractor), to avoid future problems
and risk management  A detail ed introduction to:
 The computerized maintenance management  Precision lubrication (oil and
system [CMMS] or enterprise asset management grease) including selection,
[EAM] system receipt, tering, storage, issue,
 Information and data that should be
and replenishment and the
managed
e ect these have on
 The link with work and spares/material
contamination
management
 Resonance correction
 Failure codes
 Power quality control, and
 Keeping equipment and
PRECISION SKILLS (PRECISION AND PROACTIVE
workplaces clean and organized
MAINTENANCE)
 The importance of commissioning
 What is precision and the importance of precision
 Safety practices and preparation
work
 The importance of following the correct
 A detailed introduction to:
start -up procedures
 Precision shaft and belt
 Calibration
alignment
 Precision soft foot correction
CONDITION MONITORING
 Precision mechanical and
 Overview of CM principles for mechanical and
electrical fastening electrical equipment
 Precision balancing and  The relationship between CM and
balancing tolerances/standards, planning/scheduling and operations
and  A detailed introduction of the technology and
 Other common mechanical and application of:
 Vibration analysis
electrical tasks
 Ultrasound
 Oil analysis

MOBIUS INSTITUTE
AUSTRALIA – BELGIUM – COSTA RICA – UNITED STATES
and authorized training centers in 50 countries
CONTACT: learn@ mobiusinstitute.com
www.mobiusinstitute.com
© 2018 – Mobius Institute – All rights reserved.
 Page 4 of 4

CONDITION MONITORING cont’d

 Wear particle analysis
 Electric motor testing
 Infrared analysis
 Electrical equipment and insulation
testing
 Transformer testing
 Partial discharge
 Non Destructive Testing [NDT]
 Process/performance monitoring
 Visual inspections
 The future of CM and predictive analytics

CO NTINUOUS IMPROVEMENT
 The principle of and importance of continuous
improvement, Kaizen, PDCA, and Lean
 The need to reassess business conditions and what
is critical
 Utilizing metrics to measure and improve
performance
 Benchmarking against industry and the
facilities “best day”
 The importance of es tablishing the right
KPIs
 Suggested metrics and KPIs and the most
e ective use of KPIs
 The importance of accurate data
collection
 The importance of constant communication
 Root cause (failure) analysis [RCA and RCFA]
 The importance of conducting RCA/RCFA
 The importance of making the
improvements
 How to perform RCA/RCFA
 Determining when it is justi ed
to perform RCA/RCFA and
selecting the appropriate
process
 A review of 5-whys, fault -tree,
Ishikawa, and other techniques
 A systematic approach to
determining the root cause(s),
determining the solution(s),
selecting the best solution,
implementing the solution, and
verifying the solution – all in a
cost justi ed manner
 The need for on -going education, skills, and
awareness training

VPOWER., JSC
08 Nguyen Cuu Van street, ward 17, Binh Thanh district, HCMC
Email: training@vpower.com.vn
Tel: +84 28 38 99 10 96
www.vpower.com.vn
© 2018 – Mobius Institute – All rights reserved.