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Maintenance and Reliability

Professional Master hosted by the Systems Engineering Department

Participating Departments: ME, ARE and CEM

Presentation Outline

Introduction.
Need analysis and Department capabilities.
Program learning objectives (PEOs) and students learning
outcomes (SEOs).
Program courses and mapping with (SLOs).
Degree plan
Benchmarking.
Program external and internal review.
Admission and program requirements.
Acknowledgement
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Maintenance and Reliability (MR): Introduction

Maintenance and Reliability are important factor in product and service

quality. It can be used as a strategy for successful competition in the
marketplace. It plays a critical role in preserving and prolonging equipment,
systems, and assets life cycle.

Maintenance Evolution: from necessary evil to an edge for competition

• Prediction and identification of failure,

• Planning and scheduling resources for repair,
• Scheduling & executing the repair,
• Collecting data and information for continuous improvement,
• Recently Technology such as (IoT), A I and data analytics have
transformed Maintenance Engineering and Management.
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Program Need Analysis

 Maintenance Systems are essential for the Saudi Economy.

 Maintenance contributes to vision 2030 through preservation

of systems and infrastructure.

 Industry survey indicates there is a need for a program in

maintenance and reliability.

 IAB members support the program in MR.

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Systems Engineering and KFUPM Capabilities

SE has a long history in the area of Maintenance stated in 1986 with two
courses to serve local industry.

Several books (4) are authored or edited at the Department faculty .

Several Theses/Dissertations are written by graduates of SE.

Several industry projects were conducted by SE faculty members.

Several Patents by SE faculty members.

A journal is established in 1994 and still going on for the last 27 years.
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Systems Engineering and KFUPM Capabilities

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Program Educational Objectives (PEOs)

PEO 1: Lead the execution of integrated maintenance projects

and demonstrate interpersonal skills including teamwork and
communication skills.

 PEO 2: Pursue a successful professional and career growth

through lifelong learning or advance degrees, and

 PEO 3: Conduct their work professionally and ethically with

attention to safety, environment, economic and social aspects.
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Students Learning Outcomes(SLOs)

Knowledge and understanding

1. SLO 1: Discuss and describe how IoT is used in predicative maintenance.
2. SLO 2: Identify effects of unplanned maintenance.
 
Skills
1. SLO 3: Design effective maintenance strategies to ensure systems high availability and uptime.
2. SLO 4: Apply the acquired knowledge to propose effective reliability programs.
3. SLO 5: Formulate state of the art condition monitoring models and technologies to develop
effective condition-based maintenance.
4. SLO 6: Make optimal maintenance decisions considering systems availability, environment, and
societal impact.
 
Values
1. SLO 7: Recognize ethical and professional responsibilities that professional maintenance engineers
and managers should uphold.
2. SLO 8: Lead teams to accomplish maintenance projects.
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 MX Courses
ISE 510 : Maintenance Systems management
ISE 506: Advance Reliability Engineering
EM 575: Principles of Safety and Environment
Management Systems.
ME 577: Deformation, Fatigue and Fracture of
Engineering Materials (Existing course).
ISE 515: Optimization and Simulation of Maintenance
systems.
ISE 518: Data Analytics for Maintenance & Reliability
SCE 543: Applied Artificial Intelligence in Condition
based Maintenance
ISE 543: Turnaround and shutdown maintenance
]
ISE 619: MX Project.
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 Courses versus outcomes

1. Discu 6.
ss
and 5. Make 7. Recognize
2. Identify the 3. Design 4. Propose Develop optimal 8. Lead team
Outcome Identi
fy IOT effect of effective effective effective decisions
ethical and
professional to accomplish
unplanned maintenance reliability condition concerning maintenance
use in maintenance strategies programs based availability codes in projects
Maint maintenance
Courses enanc maintenance and reliability
e

Maintenance systems .
management X X X X
Advance Reliability Engineering X X   X

Principles of Safety and

Environment Management X x X X
Systems
 
Deformation, Fatigue and
Fracture of Engineering X X
Materials X X 

A.I Application in condition-

based maintenance X X X X

Data Driven Maintenance and

Reliability
 Degree Plan

Semester I Semester II Semester III

ISE 510/ARE 525:
Maintenance Systems
management
ISE 506: Advance Reliability
Engineering
SCE 543: A.I Applications in
ISE 543: Turnaround and
Condition based
Shutdown Maintenance
Maintenance
ISE 518: Data Driven
Maintenance and
Reliability ISE 619 MX Project

EM 575: Principles of Safety ISE 515: Optimization and

and Environment Simulation of Maintenance
Management Systems systems.
 

ME 577: Deformation, Fatigue ISE 619 MX Project

and Fracture of Engineering
Materials
 
12 Cr 15 Cr 3 Cr
 Benchmarking
Manchester Cranfield Lulea Tennessee NUST
Courses Sweden Norway
ISE 510/ ARE 525 Maintenance Systems X X X X
management
ISE 506 Advance Reliability Engineering X  X X X X
EM 575 Principles of Safety and Environment
Management Systems  X   X X

ISE 515 Optimization and Simulation of

Maintenance systems.   X X X

SCE 543 .I Applications in Condition based

Maintenance. X X  X X X

ISE 518 Data Analytics Maintenance and

Reliability X   X X

ME 577: Deformation, Fatigue and Fracture of

X
Engineering Materials

ISE 543 Turnaround maintenance  X

ISE-619 MX Project X X X X X
Program Internal and External Review

Two External Reviewers

• Overlap among two courses.
• Short time for the Professional Master

Two Internal Reviewers

• Short time for the Professional Master

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IAB and Departments Program Review

IAB Review
• Suggested some topics for the courses.

KFUPM Academic Departments Review

• Short time for the Professional Master

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 ISE-510: Maintenance Systems Management
Description
Objectives
Maintenance & Facility Maintenance
Management Systems, their philosophies, trends
and prospective. Maintenance organization,
maintenance strategy and concepts, including
total productive maintenance (TPM) and
Reliability centered maintenance (RCM),
forecasting maintenance load, maintenance jobs
measurement and standards, quality of
maintenance jobs, maintenance productivity and
auditing, benchmarking, maintenance
performance measures (KPIs), CMMS, life cycle
costing, and maintenance resources control. Case
studies.
Pre-requisites: Graduate standing
Describe the role maintenance plays in
an organization.
Explain the different maintenance
strategies and their application.
Present techniqies to Determine the
optimal preventive maintenance interval
and inspections time.
Explain how to conduct a maintenance
auditing in the industry.
benchmarking, maintenance
performance measures (KPIs),
Present the role of maintenance
resources control for maintenance as
service in the aftersales market
including life cycle costing.
Back
 ISE 506 Advance Reliability

Description Objective
Role of reliability engineering in industry,
reliability measures, and bath-tub Explain the role of reliability engineering
reliability curve, and overview of in industry, interpret the meaning of
reliability assessment. Component failure reliability measures and system failure
behavior and reliability prediction based on behavior.
failure data analysis. Reliability of systems
Analyse failure data and conduct
including serial, parallel, k-out-of-n,
distribution parameter estimation of
complex systems, standby systems, and
component lifetime.
their combination. Improvement of system
reliability and reliability growth. Evaluate the availability performance
Availability of repairable systems. measure of repairable systems.
Accelerated life testing. Practical
applications and case studies from Present the role of accelerated life testing
aerospace, automotive, and manufacturing and apply it on a case. Back

industries.
Pre-requisites: Graduate Standing
ME 577: Deformation, Fatigue and Fracture of Engineering Materials.

Description
Objectives

Explain fracture failure of

Review of basic mechanical testing, elastic
deformation, stress transformation and
static failure theories. Fracture mechanics.
Stress-based fatigue for smooth and notched
members. Fatigue crack growth. Modeling
and analysis of plastic deformation. Strain-
based fatigue.
cracked materials.
Present to students fatigue due
cyclic loading and its effect on
crack initiation and growth.
Present stress-based approach
to fatigue analysis.
Explain how to analyse and
determine causes of failure.
Outline maintenance/preventive
tasks to mitigate failure. Back

Prerequisite: Graduate standing

EM 575: Principles of Safety and Environment Management Systems
Description
Principles of OHSE management and ISO
standards for safety and environment. Analysis
of the impact of OHSE and ISO on maintenance
practice. OHSE management concepts and
systems; hazards, risks and risk management
in maintenance; risk assessment and control;
ISO standards for safety and the environment,
environmental impact (risk) assessment; safe
design; Ethics in maintenance practice,
legislative and organizational context for
practice of maintenance; evaluation of
maintenance practice
Pre-requisites: Graduate
Standing
Objectives
Compare and contrast OHSE
concepts, processes and
performance measures.
Present ISO standards for safety
and environment.
Communicate technical information
and theoretical concepts effectively
with OHSE professionals in a
variety of relevant contexts.
Present environmental risk and ethics
in maintenance practice.
Analyze the main organizational,
technological, industrial law, and
socio-cultural factors that influence
OHSE-related decision making. Back
 ISE 518: Data analytics for Reliability and Maintenance
Description
Overview of Maintenance 4.0, methods of data
analysis including regression, association rules,
clustering and classification algorithms, design
predictive models by automated data mining,
prediction of remaining useful life and future
failure/alarm by analyzing equipment condition
data, design diagnostic and prognostic systems
for predicative and proactive maintenance and
methods of evaluating predication models.
Pre-requisites: ISE 510 or 529, ARE 525 and ISE
505 or ISE 506.
Objectives
Present maintenance data minimg to
get useful knowledge, hidden
patterns and relationships.
Explain diagnostic system to predict
future failures and possible alarms.
Cover prognostic systems that
improve productivity of equipment
and monitor the remaining useful life.
Discuss critical factors affecting the
performance of equipment or
reliability of a system.
Present approaches for Designing and
evaluating predictive models.
Back
 SCE 543: A.I Applications in Condition-Based Maintenance
Description
Intelligent maintenance components.
System Operation in a lifecycle perspective.
Type of failures in equipment and
machinery during operation, and failure
causes. The influence of these failures on
efficiency, safety and the environment.
Condition monitoring and inspection
methods. Sensing technology, sensor
network and IoT. Artificial Intelligence (AI)
and Machine learning algorithms such as
Neural Networks (Deep), Support Vector
Machine, reinforcement learning and
others for the detection of precursor for
failure and their root causes; and for
preventive and predicative maintenance.
Case studies
Pre-requisites: ISE-510 or ISE 529 or ARE
Objectives
• Motivate for the need for intelligent
maintenance and its different.
- Determine the different sensor
technology for industrial fault detection
and isolation (FDI).
- Present the different model-based and
data driven techniques to assess
system’s health.
- A.I and machine learning techniques
for failure detection and their root
causes and prevention.
- Present state-of-art technologies
strength and limitations.
Back
 ISE 515: Optimization and Simulation of Maintenance
Systems

Description Objectives

Mathematical programming models that Pesent optimization and

include linear, nonlinear and chance constrained
programming and their application in various
areas of maintenance.: Maintenance capacity
planning models, maintenance resources and
shared resources and services for large
organizations, component replacement models,
Block replacement models, models for spare
parts provisioning, models for condition-based
models including proportional hazard models
Pre-requisites: ISE-510 or ISE 529 or ARE
simulation models to represent
key maintenance system or
subsystems.
Cover algorithms to solve and
validate the formulated models.
discuss the applications and how
to use the results of optimization
and simulation to improve the
performance of maintenance
systems Back

525.
 ISE 543: Turnaround and Shutdown Maintenance
Description
Introduction to TAM. TAM concept.
Systems approach to TAM. The phases of
TAM, scoping, preparation, execution, and
start-up. Critical elements of TAM. , scope
planning, work load estimation, scheduling
of TAM activities. TAM contracts, Critical
path analysis, execution, and monitoring.
Analysis of TAM life cycle and performance
measurements (KPIs). Ethics in
maintenance practice, Reporting, learning
from TAM experiences and continuous
improvement. Life cycle costs for
equipment.
 Pre-requisites: ISE-510 or ISE 529 or
ARE 525.
 
Objectives
Presents the elements and stage
of a sound TAM.
Cover all the steps for planning,
mobilizing, scheduling,
executing and closing a TAM
and shutdown maintenance..
Discuss how to assess and
measure the effectiveness of
the process of conducting TAM.
Present the process of
improving TAM.
Back
 ISE 619 Project
Description
A graduate student will arrange with a
faculty member to conduct an industrial
research project in the areas of
Maintenance and Reliability preferably in a
local plant. The project shall include
diagnosis of an existing problem or
identifying an area of improvement. The
problem or area of improvement will be
demonstrated by data analysis, problem
formulation, a suggested approach for
solving the problem or realizing the
improvement. Then implementation,
validation and repot writing.
Prerequisite: Completion of at least 12
credit hours in the program.  time delay, over run cost, … etc.
Objectives
Identify Maintenance and Reliability
best practices as it applies to a specific
Industry.
Develop measures to use to identify
problems or areas in maintenance and
reliability that need improvement.
Formulate an integrated approach to
improve maintenance or reliability
practice.
Apply the integrated approach to
resolve problems or improve existing
maintenance or reliability practice.
Develop a project control measures to
mitigate causes of projects failure e.g.
Back
Admission Requirement

Batchelor in Engineering with min CGPA

2.75
TEOFL with 70 IB or ILETs score of 6.
KFUPM with an average of B in the three
English courses.
Interview if needed.
Two years of experience in the field is a plus.

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Admission Requirement

The program requires background in the following areas;

 Probability and statistics or equivalent.

 Material science or Mechanics of material. In terms of courses
(ME 217 0r ME 305. OR CE 203 for new programs of Petroleum,
Civil and Architectural Engineering. Or CE 202 and CE 203
(Structural Mechanics) . However if an old graduate we check the
background to see if he has taken courses in failure mechanics.
 Students in majors that do not take material science or
Mechanics of material will advised to take ME 305 or ME 216 to
build the needed background for ME 577.

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Program Committee

Dr. SaLih Duffuaa Professor and Program Systems Engineering

Coordinator
Dr. Sami El-Ferik Associate Professor Systems Engineering

Dr. Ahmad Al-Hanbali Associate Professor Systems Engineering

Dr. Hany Osman Assistant Professor Systems Engineering

Dr. Abdel Mohsen Al- Professor Architectural Engineering

Hamad
Dr. Jafar Hussain Ali Associate Professor Mechanical Engineering
Albinousa
Dr. Awsan Mohammed Assistant Professor Construction Engineering
Management

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Students Background

Let students introduce themselves.

Education background [University and
Major].
Experience
Why attracted and selected this program

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