5002 – Introduction to Reliable Manufacturing

The Introduction to Reliable Manufacturing® course lays the foundation for organizations seeking to achieve world-class reliability through cultural transformation, technical excellence, and proven methodologies.

This training session provides an in-depth overview of what it takes to transition from reactive to reliable manufacturing. Participants will gain insight into the core principles of asset reliability, workforce development, and the integration of reliability best practices at all levels of the organization.

We ask critical questions: What needs to change in mindset, culture, and skill sets? How do we build sponsorship and advocacy for reliability? And most importantly, how do we connect these efforts to measurable results on the bottom line?

Throughout the course, participants will engage in a mix of presentations, demonstrations, field observations, and challenges designed to provide a clear understanding of the steps needed to begin — or accelerate — their journey toward Reliable Manufacturing®.

What You Will Learn

By attending this course, participants will:

• Understand the definition and pillars of Reliable Manufacturing®
• Recognize how machine failure patterns can be traced to specific behaviors, practices, and design flaws
• Explore the business case for investing in hard skills and craft capability
• Learn the roles and responsibilities required across functions to support a culture of reliability
• Examine how Precision Maintenance®, Operator Care, and Condition Monitoring work together to create sustainable performance
• Discover how to develop improvement processes that qualify people, quantify value, and track progress

Course Content

Introduction to Reliable Manufacturing®

This introductory section establishes the foundation for the rest of the course. We begin by defining the term Reliable Manufacturing®, highlighting its role in creating predictable, safe, and high-performing industrial environments. Participants will explore the strategic reasons for shifting toward reliability and how this shift benefits safety, productivity, quality, and cost control.

Topics include:

• Introduction to Reliability Solutions Monitoring
• Defining Reliable Manufacturing® and its key principles
• The journey to Reliable Manufacturing®: phases and pitfalls
• Building a predictable, high-performing plant
• Why hard skills matter: the case for hands-on craft training
• Understanding the patterns and sources of machinery failure
• Symptom vs. root cause: what are you treating?

This section also emphasizes the importance of leadership commitment, change management, and cross-functional collaboration in achieving sustainable improvements.

Reliable Manufacturing through Precision Maintenance®

Precision Maintenance® is the technical backbone of reliable manufacturing. This module explores how correct installation, alignment, balance, and assembly of components directly influence equipment life and reliability. Participants will learn how to identify and eliminate common craft errors that compromise asset health and increase maintenance costs.

Topics include:

• The evolving role of today’s craft technicians
• The impact of misalignment, unbalance, and poor assembly
• Introduction to essential craft skills and their value
• Cost-benefit analysis of Precision Maintenance®
• Examples of lifecycle improvements through precision techniques
• Precision tools, tolerances, and quality control measures

This session also addresses how to qualify technicians and ensure continuous skills development across the maintenance workforce.

Reliable Manufacturing through Essential Operator Care

Operators are the first line of defense in asset care. In this section, participants will learn how to empower operators with the skills, tools, and responsibilities needed to actively contribute to equipment reliability. We explore how early detection of anomalies, proper daily inspections, and ownership of routine care tasks can dramatically reduce failure rates.

Topics include:

• Defining Essential Operator Care (EOC) and its importance
• Creating “N.I.R.D.s” – Naturally Interested and Responsible Detectives
• Working with the P-F Curve: early detection and intervention
• Structuring effective inspection routes and routines
• Providing the right tools and training for frontline ownership
• Building a partnership between operations and maintenance

Operator engagement isn’t just a technical issue — it’s a cultural one. This module focuses on how to create buy-in, reinforce accountability, and build pride in ownership.

Reliable Manufacturing through Condition Monitoring

Condition Monitoring is essential for assessing asset health, preventing unexpected failures, and making informed maintenance decisions. This section introduces participants to the concepts, tools, and best practices for online and offline condition monitoring — and how to integrate them into a reliability program.

Topics include:

• What is Condition Monitoring? Definitions and benefits
• Understanding roles and responsibilities in asset condition assessment
• Vibration analysis, thermography, oil analysis, and other technologies
• Selecting the right assets and methods for monitoring
• Turning data into decisions: reporting and acting on results
• Real-world examples of condition monitoring success

This module emphasizes the role of skilled analysts and proper diagnostics in reducing unnecessary maintenance and improving asset performance.

Bringing It All Together: Implementation and Action Planning

In the final section, we focus on practical steps to implement the lessons learned across the organization. Reliability is not a one-time initiative; it’s a long-term commitment that requires structure, leadership, and measurable progress.

Topics include:

• Strategies to drive Reliable Manufacturing® at the corporate and site levels
• Identifying early signs of success and maintaining momentum
• Communicating and celebrating reliability wins
• Creating qualification and recognition systems for your workforce
• Defining and tracking key performance indicators (KPIs)
• Review of next steps: building your action plan

Participants will leave this session with a clear understanding of how to tailor the Reliable Manufacturing® approach to their specific site, workforce, and challenges.

Why Choose This Course?

This isn’t just a theory-heavy workshop. It’s a high-impact, action-oriented course designed to create a shift in how your organization views reliability. We combine years of field experience, proven frameworks, and practical exercises to deliver real value. Every concept is tied back to measurable business outcomes.

You’ll leave with:

• A clear vision of what good looks like in Reliable Manufacturing®
• The ability to diagnose current gaps and opportunities
• A roadmap for engaging leadership and the front line
• Practical next steps to begin transforming your site