THE GROWTH PATH FOR ASSET RELIABILITY PRACTITIONERS
ASSET RELIABILITY PRACTITIONER [ARP]
The Asset Reliability Practitioner [ARP] series of courses and certification levels was developed for people seeking to achieve higher levels of site performance through improved reliability. We provide a growth path from the advocate who is starting their journey, through the reliability engineer who is the technical master, to the reliability program manager who must run an effective program. At the beginning of 2020, there were already over 1,000 people certified, and many more trained.
What is ARP?
Improving the reliability and performance of an industrial facility is so important. The facility will be safer, have fewer environmental incidents, will provide security and job satisfaction to employees, and financial rewards to the owners and shareholders. If you are a part of the team tasked to improve reliability, the ARP program will start by teaching you the big picture [ADVOCATE level], educate you on how to be an effective Reliability Engineer [RELIABILITY ENGINEER Level], and train you on how to lead a successful implementation [RELIABILITY PROGRAM LEADER Level].
You can earn an internationally respected certification that recognizes your knowledge and time in the industry, or you can progress further and become recognized for your proven experience. Attending the JumpStart your Reliability Journey workshop can be the start of your journey.
ARP-A] RELIABILITY ADVOCATE
Those new to reliability can start with the ARP-A “Reliability Advocate” short course. Whether you are trying to get your head around the big picture of reliability improvement or learn how you can contribute to an existing program, the three-day ARP-A Reliability Advocate course will provide the depth and breadth required.
[ARP-A] IN DETAIL
The best way to begin the reliability journey
Where are you on the journey to reliability improvement? If you are new to the program, or you are interested in learning more so that you can begin a new program at your plant, then the Asset Reliability Practitioner [ARP-A] "Reliability Advocate" course is precisely what you need.
Improving the reliability of physical assets takes far more than just monitoring their condition, improving lubrication practices, and making some improvements to the maintenance department. To have a truly successful program you must understand how to add value to the organization and thus gain senior management support. You must have the support of the entire organization, not just a small group of evangelistic condition monitoring and reliability experts. You must have a coordinated effort between maintenance, operations/production, engineering, finance and the reliability group – no more silos. And you must follow a strategy that will enable you to build the program, layer upon layer, to achieve milestones and build on success.
Yes, we could simply talk about the common reliability acronyms of RCM, PMO, RCA, and literally dozens of others, but knowing what they mean does not help you implement a successful program.
The ARP-A Reliability Advocate program will provide a holistic view of how to improve reliability and plant performance. It will explain the implementation process and all the essential elements necessary to have a truly successful program.
How much detail will we cover?
We only have three days together, and that includes plenty of time for discussions and case studies, so it is not possible to get into the details of every topic. The goal is to explain what it takes to be successful and how to avoid all the traps that have caused so many programs to fail. Public courses are conducted around the world, but to gain the greatest value, invite the instructor to visit your facility and gather the entire team together.
The course follows the Asset Reliability Transformation [ART] implementation process; however, it is totally up to you whether you follow our recommended practices.
After three days, you'll have a clear understanding of why you should improve reliability and how to implement the successful program. Plus, you will be ready to take the exam so that you may be recognized for your knowledge under the Mobius Institute Board of Certification [MIBoC] accredited program.
A summary of the subjects covered on the ARP-A Reliability Advocate course
The course begins with a summary of why reliability improvement is so important to the future of an organization. But then it busts the myths associated with reliability improvement; there are so many misunderstandings in industry that it is essential to get everyone on the same page so you avoid the common traps.
Next, we provide an overview of the implementation process: how to get started, how to gain senior management support, how to change the reliability culture so behaviors change, how to break out of the reactive maintenance cycle of doom, and how to establish a sustainable reliability improvement initiative. If you already have a program, you will learn how to assess its progress and re-focus and re-energize it.
More than one day is spent on the common technical elements of reliability improvement. You will feel comfortable with defect elimination, the asset strategy (including Reliability Centered Maintenance, Preventive Maintenance Optimization, and Failure Modes, Effects, and Criticality Analysis), the asset criticality ranking, Pareto analysis, precision maintenance, and asset care, operator driven reliability, condition-based maintenance and all of the common technologies, lubrication best practices and contamination control, precision shaft alignment and rotor balancing, and root cause analysis. Yes, there are a lot of topics, but with our unique simulations and animations, you will be amazed at how confident you will feel with the subjects once you've completed the course.
Between the discussions, lessons, case studies, and polling (so you can make sure you understand what you think you understood), you will come away with a totally new perspective on how to improve reliability and performance in your organization.
[ARP-E] RELIABILITY ENGINEER
The path to improved reliability involves a variety of technical challenges, and the ARP RELIABILITY ENGINEER course (and exam) prepares you for those challenges. The challenges include the development of the asset strategy with techniques such as RCM, FMECA, and PMO, criticality analysis, RCA, reliability data analysis (Weibull, Crow AMSAA, and others), establishing a condition monitoring program, precision, and proactive maintenance, and so much more!
The five-day course is intensive, but worth it - the topics covered are essential.
[ARP-E] IN DETAIL
The best way to master reliability engineering
The reliability engineer must be quite versatile. They must understand a broad range of technical subjects and be capable of applying them all. If you are up for the challenge, the Asset Reliability Practitioner [ARP-E] "Reliability Engineer" course is just what you need.
You will have 4 1/2 days to master everything from defect elimination, asset strategy development with RCM, PMO, and FMEA, planning and scheduling, spares and materials management, condition monitoring, precision maintenance practices, reliability data analysis, criticality and Pareto analysis, root cause analysis and FRACAS, lubrication and asset care, and other topics.
There is a lot to learn, but to be a successful reliability engineer, you must learn it all. Fortunately, the Mobius Institute training techniques will ensure that you will not just survive the course, you will enjoy it, understand all the topics, and feel confident in the role of a reliability engineer.
A basic summary of the course
After a brief introduction into the strategy and the role of the reliability engineer, we will take a deep dive into reliability engineering data analysis, including statistical analysis, Pareto analysis, Weibull analysis, Crow-AMSAA, and other techniques including AI, machine learning, and predictive analytics.
Then we will explore risk assessment and risk analysis, including asset criticality ranking.
Next, we will explore defect elimination and look at the entire lifecycle of the asset, from the project management and design (including designing for reliability, availability, maintainability, safety i.e. RAMS, plus energy efficiency), the procurement process, acceptance testing, through the maintenance and repair process, through to operations.
Then we will take a deeper dive into how to minimize equipment failure by developing an asset strategy (also known as the strategic maintenance plan). We will discuss fault tree analysis (causal tree analysis), Reliability Centered Maintenance (RCM), Failure Modes, Effects, and Criticality Analysis (FMECA), and Preventive Maintenance Optimization (PMO).
Next, we will look at how we can apply a disciplined approach to the way maintenance is performed. We will begin with a discussion of developing a master asset list, bill of materials [BoM], and a management of change [MoC] process. Then we will discuss work management and spares/materials management. While the reliability engineer can't control what the maintenance department does, you will certainly understand planning and scheduling best practices and how to achieve the best outcome.
Adding to the discussion of work management is a detailed look at precision and proactive maintenance for rotating machinery, electrical equipment, and other asset types. The training will include lubrication application and contamination control, precision laser and belt alignment, precision fastening (electrical and mechanical), and precision balancing.
Next, the course will take a close look at the condition monitoring program and all of the key technologies: vibration analysis, ultrasound analysis, oil and wear particle analysis, infrared thermography, electric motor testing, electrical and power quality testing, transformer testing, partial discharge, NDT, and performance monitoring.
And finally, time is spent on the details of root cause analysis and the Failure Reporting, Analysis, and Corrective Action System or FRACAS. This is an important component of any reliability program and we cover problem-solving and project management.
If you are wondering whether 4 1/2 days is enough time to feel comfortable with all of these topics, then we highly recommend that you take advantage of the Mobius Institute learning zone and view the lessons online before the course. And if after the course you still have any areas of doubt, watch the videos again.
But remember, we have the famous Mobius Institute simulations and animations that make these technical topics far easier to learn and understand.
[ARP-L] RELIABILITY PROGRAM LEADER
The ARP RELIABILITY PROGRAM LEADER course and certification program is for the true leader of the reliability and performance improvement initiative. Someone must guide the Reliability Engineers and liaise with senior management and other plant management. The main focus of the course is to understand the economics of reliability and establish the value of the program to gain the commitment of senior management, to develop the strategy, and to establish a culture of reliability and performance.
This is also a five-day course, but you will learn so much - there is no other like this in the industry.
[ARP-L] IN DETAIL
For the true leader of the reliability improvement initiative
What a great opportunity you have. Improving reliability will make the plant safer and more competitive. Your fellow workers will have greater job security and they will enjoy a greater sense of job satisfaction.
But that’s only if you are successful with the program…
You, therefore, have a great weight on your shoulders. Not every reliability improvement initiative is successful; sadly, far from it.
We have defined this course to help you to be successful with your program. We don’t know of any other training course like it. Success in reliability leadership comes from understanding the value of the program (and communicating that value), having a detailed strategy, and engaging with the entire organization so everyone is pulling in the same direction. Those topics are the main focus of this training course.
Yes, this course will also discuss many of the essential elements that must exist to have a successful, sustained program, but for the most part, it will be your reliability engineers who must understand the details of those elements.
Leadership versus program management
It is all too common for people to view reliability improvement as a technical challenge, and therefore the role of the manager of the program simply to facilitate the technical solution.
And that is one of the major reasons why so many programs fail.
This training course is not about managing a technical program. It is about leading a successful, sustained initiative that achieves the highest levels of performance through improved reliability and reduced waste.
The leader must deliver value to the organization, and therefore they must understand what that means for their organization. The leader must change the culture and sustain the enthusiasm and engagement of all employees.
The leader must establish a strategy that steers around the quicksand and continually add value.
This course will explain how to do just that.
A basic summary of the course
In brief, we will explain the implementation process, educate you about the economics of reliability, and then explain how to establish a new program or reinvigorate an existing program. By the end of this process, you will have the support of senior management which is so critically important.
Next, we will focus on how to develop an engaged, educated, and qualified workforce. We will start with a discussion of the psychology of reliability, discuss human error and human error management, and then take a very close look at the culture change process. As part of that process will discuss how to ensure everyone buys-in and contributes to the program.
One of the most common reasons for programs to fail is they cannot break out of the “reactive maintenance cycle of doom”. So that’s the next major topic we will discuss; a step-by-step guide to greatly reducing the volume of breakdown maintenance work.
By this stage, we will have senior management support, a detailed strategy, an educated and skilled workforce that is developing a reliability mindset, and a maintenance group that is no longer frustrated by endless breakdowns. Now we can step it up a gear and work towards “world-class” performance.
While the technical details will be handled by your reliability engineers and people in the maintenance, engineering, and operations/production departments, you must understand how to drive the organization towards best practices.
We will begin with a discussion of defect elimination in the area of project management, design, procurement, and contractor management. Everything the organization acquires must be fit for purpose.
Next, we will focus on how to establish discipline in the way we perform all maintenance tasks, manage our spares, and the way we operate equipment. A disciplined approach will set up our equipment for successful operation. One of the requirements is to have an effective asset strategy (strategic maintenance plan) so we will discuss the outline of that development process.
To keep the equipment operating smoothly with trouble-free operation, we must care for those assets. We need the equipment to remain in healthy condition, and we must operate them with standard operating procedures. This section will also cover precision lubrication and 5S.
And finally, in order to improve everything we are doing, from the maintenance decisions we make with condition monitoring, to the changes we make in our program, we must make data-driven decisions, we must learn from failures, and we must continually optimize everything we do.
If you would like to know more about the topics covered on the course, you may enjoy reading the pages on our site related to the Asset Reliability Transformation [ART] process. We will be following that process, step-by-step.
Early in the course, we have modules on the “Economics of reliability”, the “Psychology of reliability”, “Human error and human error management”, and “Culture change” in order to build the knowledge necessary to excel in the VALUE, STRATEGY, and PEOPLE phases, but from that point on we will basically summarize the core elements of the ART roadmap with a little less detail (because the reliability engineers are the team members who must understand the details).
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