MOBIUS INSTITUTE Reliability Products

iLearnReliability[Professional Development]
Training module details contained in iLearnReliability [Professional Development]

iLearnReliability[Professional Development]
provides the perfect coverage of topics and self-
paced training style to ensure you achieve your
goals. Mobius Institute creates successful reliability
champions through iLearnReliabilitys unique
approach to learning. These two series of training
modules utilize animation, simulations, quizzes and
an unsurpassed training methodology that makes
complex concepts easy to learn and understand.

Essential Elements [EE]

The Essential Elements [EE] modules provide initial
orientation of all of the reliability improvement
topics covered in each respective version of
iLearnReliability and can be used later for refresher training.

Program Management Training [MT]

The Program Management Training [MT] modules are intended for reliability engineers, PdM program
managers, and other people who are charged with implementing the reliability improvement and PdM
(CBM) program. These people generally do not need the same level of knowledge as the people who will
actually use the condition monitoring tools and software, or the people who will work on machines
(alignment, balancing, lubrication, etc.) but they do need to have a good working knowledge of those
topics, and they certainly need to know how to run a successful program.
 MOBIUS INSTITUTE Reliability Products

Essential Elements [EE]

iLearnReliability includes a series of brief modules called Essential Elements [EE] that provide a quick introduction to key reliability topics
and can be used as a handy reference or refresher.

Code Title Slides Description

This module provides a quick introduction to the Roadmap to Reliability; the core
strategy behind iLearnReliability. Roadmap to Reliability provides a strategy for defect
Roadmap to
EE-RR 54 elimination which includes condition monitoring, reliability centered maintenance,
Reliability
precision skills and guidance which are used alongside these tools to develop the
reliability culture.

Your fundamental goal as a reliability professional should be to identify the root cause of
the defects and proactively eliminate them. Taking proactive steps to eliminate the root
Defect
EE-DE 67 causes of equipment failure is also known as, Defect Elimination. This module covers
Elimination
some common sources of defects, defect justification and how to use condition
monitoring for QA/QC.

Beginning to understand criticality analysis and the asset criticality ranking are the main
goals of this module. Developing an asset criticality ranking is an essential step in the
Asset Criticality
EE-ACR 55 reliability improvement process, it enables work to be prioritized and investments
Ranking
justified. This module discusses the likelihood of failure, Risk Priority Numbers (RPN) and
the detectability of the warning signs that must also be taken into consideration.

The classic Reliability Centered Maintenance (RCM) strategy ensures the function of an
Reliability asset is preserved without compromising safety or the environment. The main outcome
Centered is to determine the proactive tasks that can be performed to meet that goal. In this
EE-RCM 62
Maintenance module, we will review the roles of maintenance, as well as the reliability centered
[RCM] maintenance process which covers operating context, failure modes, task intervals and
more.

This module focuses on several different types of maintenance practices; from reactive,
Maintenance proactive and preventive maintenance to planned, precision and run-to-failure
EE-MP 57
Practices maintenance. Some of these terms, and your understanding, are often broadly used, but
in this module, we will begin to clarify each of their differences.

The FMEA (Failure Mode and Effects Analysis) process is the examination of failure
Failure Mode modes, the effects and consequences of failures and the focus on determining how to
EE-FMEA and Effect 47 deal with those failure modes. This in-depth module begins to explain the purpose and
Analysis [FMEA] benefits of using the FMEA process versus the Root Cause Failure Analysis (RCFA)
method.

Preventive The Preventive Maintenance Optimization (PMO) process should reduce maintenance
Maintenance costs, increase availability and identify interval-based maintenance tasks that were not
EE-PMO 27
Optimization previously being performed. In this module, we will discover where preventive
[PMO] maintenance tasks come from and why these tasks are necessary.

Just because condition monitoring test are being performed on your equipment does not
Condition
mean that you are properly improving reliability of that equipment. The condition based
Based
EE-CBM 50 maintenance technologies discussed in this module can be used to detect the root
Maintenance
cause of failure and well cover how those technologies can be used in QA/QC function;
[CBM]
checking installations, performing acceptance testing, etc.

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This module provides an overview of vibration analysis; a vital tool in seeing inside the
machine. This module covers how to measure vibration to determine the health of
Vibration
EE-VIB 72 rotating machinery by utilizing overall-level readings, time waveform and spectrum
Analysis
analysis. You will learn why vibration analysis is so vitally important in any condition
monitoring and defect elimination program.

This module introduces you to ultrasound analysis and how to use it to detect
Ultrasound mechanical, electrical and process faults so that you can reduce failure rates and energy
EE-UT 56
Analysis consumption. Leak detection, mechanical and electrical applications, as well as stream
traps are a few of the topics that are covered in this module.

Infrared thermal imaging, also known as Infrared thermography, is a powerful tool that
Infrared
can be used to detect faults in mechanical and electrical equipment. In this module, we
EE-IR Thermal 46
discuss theory as well as the electrical, mechanical and other industrial applications that
Imaging
benefit from this type of condition monitoring tool.

Precision shaft alignment is essential if you value equipment reliability. This module is an
EE- Precision Shaft introduction to machine shaft alignment with dial indicators and laser alignment systems.
60
ALIGN Alignment We will discuss pre-alignment checks, straightedge and dial indicator alignment as well
as proper methods to correct misalignment.

The module on precision balancing is an introduction to correcting machine rotor

Precision unbalance. Bearings, shafts, seals and foundations will all last longer in precision
EE-BAL 49
Balancing balanced machines, thats why it needs to be a key element in your plan for reliably
improvement.

This module focuses on how you can extend the life of all rotating machinery and the
Lubrication
lubricants themselves by controlling lubrication contamination. We will discuss why
EE-CC Contamination 54
contamination is so harmful, how to minimize contamination, contaminants that affect the
Control
surface and the importance of precision lubrication.

Preventive maintenance (PM), which is also known as interval-based maintenance,

should be a part of a broader maintenance strategy that includes condition-based
Preventive
EE-PM 57 maintenance and run-to-failure maintenance. This module explores when you should use
Maintenance
preventive maintenance, the goals you should have to preserve function and how to
develop a preventive maintenance strategy.

This module covers the benefits of using operator driven reliability to performing simple
condition monitoring tasks and inspections, adjustments and perform elementary
Operator Driven
EE-ODR 33 maintenance tasks. By utilizing operator driven reliability as part of your reliability initiative,
Reliability
you will free up dedicated maintenance and condition monitoring personnel so that they
can be more productive and effective.

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Program Management Training [MT]

Program Management on MANAGEMENT topics [MT-M]
These Program Management Training [MT] modules are focused on Management [M] topics. These modules are intended to ensure that a)
the benefits of condition based management and reliability improvement are fully understood, b) the steps required to successful start and
maintain a successful program are understood, and most importantly c) the steps required to gain buy-in from upper-management through
to the plant-floor staff are fully understood.

Program Management on CONDITION MONITORING topics [MT-CM]

These Program Manager Management [MT] modules are focused on Condition Monitoring [CM] technology topics. These modules will
provide a very strong base of knowledge on all of the condition monitoring technologies so that it is possible to speak with confidence to a
sales person selling the systems, and carry on a sensible conversation with the condition monitoring specialist, whether he or she is a
consult or an in-house employee.

Program Management on PRECISION MAINTENANCE topics [MT-PM]

These Program Management Training [MT] modules are focused on Precision Maintenance [PM] topics. These modules will provide a very
strong base of knowledge on all of the precision maintenance techniques such as precision alignment and balancing, resonance
elimination, precision lubrication, optimal operation, correct fastening, and other reliability improvement areas. It is assumed that the person
taking these modules does not require the knowledge to perform these tasks but does need to fully understand how they are done so that
purchase decisions can be made, work practices can be established, and correct practice is recognized.

Code Title Slides Description

This Management Training [MT] module is the key training module in the
iLearnReliability series. This learning module (and the associated PDF document)
takes you by the hand and explains how to achieve the transformation from reactive
Roadmap to
to reliable at your plant using iLearnReliability. It presents the decisions you will have
MT-M-1 reliability 240
to make, and it will help you to determine where you are along the path. It makes
improvement
recommendations regarding who should receive training and recommends which
training modules should be used however, you are free to use any lesson modules
for any people.

This Management Training [MT] module provides a detailed overview of maintenance

practices. After discussing perils of working in a plant that only practices reactive
maintenance, the module moves on to a discussion breakdown maintenance (pros
and cons) and preventive maintenance (and why the strategy can be flawed for
rotating machinery). Next the module introduces condition based maintenance
Understanding
strategy. We explain the benefits of basing maintenance on condition, and provide
MT-M-2 maintenance 200
an overview of each condition monitoring technique. And finally, we discuss how
practices
the greatest reductions in maintenance costs, energy consumption, inventory costs
and production losses are gained through reliability improvement. We provide an
introduction to RCM but then explain how most plants can make huge gains by
focusing on precision alignment and balancing, proper lubrication and
fastening/torqueing, resonance elimination, and other techniques.

This Management Training [MT] module explains the importance of developing a

vision statement, a plan, and a set of targets. The vision statement, and leadership
Setting the
from the top, is essential to the success of this program. If you dont have goals,
targets: KPIs,
and you dont have a plan, then it is impossible to measure your progress.
MT-M-3 benchmarking, 50
Identifying and addressing the gaps are an important part of the continuous
and continuous
improvement program. In addition to providing a set of leading and lagging KPIs,
improvement
with guidance on how to acquire the data, we provide a helpful benchmarking tool
so that you can compare yourself to best practice in your industry.

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This Management Training [MT] module is aimed at helping you understand the
psychology of your fellow human beings, and navigate the change process. The
Leadership and best plan and vision in the world will fail unless you address the human factors. The
MT-M-4 70
culture change culture in your plant will need to change, and the human-error issues will need to be
addressed. Your only tools are communication and training; you need to manage
both correctly.

This Management Training [MT] module explains the need for a Master Asset List; a
list that documents all of the assets that relate to the reliability of the plant, tagged
with information documenting the location and function of the asset. This module
Building a Master explains why you need such a list and how to develop the list even if you dont
MT-M-5 40
Asset List already have a Computerized Maintenance Management System (CMMS). If you
already have a functioning CMMS, then it will be unnecessary to go through this
module (unless you want to check that your CMMS contains the required
information).

This Management Training [MT] module provides guidance on how to assign the
criticality to each asset and function. It is impossible to proceed with the reliability
Establishing the improvement program without an accurate assessment of criticality. Without it, it is
MT-M-6 Asset Criticality 115 impossible to justify which maintenance strategy should be applied to each asset.
Ranking This module describes how you can involve different stakeholders from the
maintenance, production, quality control, engineering, and health and safety
departments to build a Master Asset List ordered by criticality.

This Management Training [MT] module explains the importance of understanding

the criticality of your assets and then, starting from the most critical asset and
working down, determining the failure modes of your assets, the probability of
Determining your
failure, and the effects of the failure. The aim is to determine which assets should be
asset
MT-M-7 105 part of the condition based maintenance program (and which
maintenance
technologies/monitoring methodologies should be applied), which assets should be
strategy
part of a preventive maintenance program, and which assets should receive
precision maintenance (and which techniques should be applied). All of these
decisions have a technical and financial basis.

This Management Training [MT] series of lessons is intended for the person who
intends to start a condition monitoring program, the person who has started a
condition monitoring program but wants to check that it is set up correctly, and the
person who wants to better understand the vibration program in their plant. The
Establishing a
module presents a structure plan and then goes through all the key steps: selecting
new vibration
MT-M-9 250 the machines to monitor, determining the best measurement strategy, selecting the
monitoring
measurement types, choosing the best measurement locations, options for
program
mounting the sensor, specifying and controlling test conditions, selecting the optimal
measurement settings, building the database, establishing baseline data, and setting
alarms. The focus is clearly on vibration analysis, but many of its messages are
equally valid for other technologies.

This Management Training [MT] is intended for the person managing the vibration
monitoring program, or anyone interested in establishing a successful program or
Supercharging an
improving an existing program. This module goes through eight major areas that
existing vibration
MT-M-10 150 should be optimized in any vibration program in order to extract the maximum
monitoring
benefit from the skills of the vibration analyst: acceptance testing, the detection
program
phase, the analysis phase, the diagnostic phase, the reporting phase, the correction
phase, the improvement phase, and the verification phase.

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This Program Management Training [MT] module provides an overview of each of

A brief
the condition monitoring technologies: vibration analysis, ultrasound, oil analysis,
introduction to the
wear particle analysis, thermography, electric motor testing, performance monitoring
MT-CM-1 Condition 75
and inspections. This module is simply intended to provide an introduction for the
Monitoring
person who does not require the more detailed training provided in the other
technologies
remaining MT-CM modules.

This Program Management Training [MT] module provides a detailed introduction to

vibration analysis, describing the different types of readings that can be taken, a little
Vibration analysis about how those readings can be interpreted, and how the data is typically collected
MT-CM-2 and bearing fault 95 (i.e. different monitoring systems). Topics include: overall levels, spectra,
detection waveforms, phase and orbits, plus the monitoring systems: walk-around, periodic
monitoring, and protection systems. The module also covers the unique high
frequency techniques designed to detect rolling element bearing defects.

This Program Management Training [MT] module provides a detailed introduction to

the use of airborne and structure-borne ultrasound for condition monitoring. Topics
Airborne and
include: understanding ultrasound, airborne measurements, structure-borne
MT-CM-3 structure-borne 50
measurements, mechanical applications (bearings, lubrication, and other rotating
ultrasound
machine faults), electrical faults (arching, corona, etc.), and process applications
(detecting leaks and steam trap issues).

This Program Management Training [MT] module provides a detailed introduction to

oil analysis and wear particle analysis. The module starts with an introduction to the
Oil analysis and importance of lubrication and the field of oil analysis; determining if the lubricant is fit
MT-CM-4 wear particle 70 for purpose, assess the properties, detecting particles, and detecting contamination.
analysis It then discusses wear particle analysis; detecting contaminants and look for
particles that indicate that wear is occurring. A range of test methods are
introduced.

This Program Management Training [MT] module provides a detailed introduction to

motor current signature analysis (to primarily detect broken rotor bars), electrical
On-line and off-
signature analysis (using voltage and current) to detect mechanical and power
MT-CM-5 line electric motor 50
supply problems; and motor circuit analysis to detect mechanical, electrical and
testing
insulation problems. The module begins with a description of how induction motors
work.

This Program Management Training [MT] module provides an overview of the

application of infrared (IR) thermography to the condition monitoring of rotating
Infrared machinery, electrical apparatus, and plant process application. Infrared energy is
MT-CM-6 55
thermography briefly introduced and spot radiometers and infrared cameras are described. The
module does not go into a lot of theory, but important issues such as emissivity, test
conditions and optical issues are explained.

This Management Training [MT] module provides a detailed introduction to shaft

Precision shaft alignment. Topics include: why is misalignment so destructive, pre-alignment
MT-PM-1 100
alignment checks, soft-foot testing and correction, dial indicator techniques, laser alignment
techniques, thermal growth, and moving the machine.

This Management Training [MT] module provides a detailed introduction to field

balancing. Topics include: why is unbalance so destructive, the basics of
MT-PM-2 Field balancing 65 unbalance, determining if a machine is out of balance, single plane balancing, and
overview of two plane balancing, tolerances and the importance of precision
balancing.

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This Management Training [MT] module provides a detailed introduction to the key
Precision role lubrication plays in the reliability improvement process. It provides a number of
lubrication (and demonstrations of the financial benefits of precision lubrication and then explains
MT-PM-3 55
contamination how the wrong lubricant and contaminated lubricant can affect bearings, gears and
control) hydraulic systems. It also explains how a lack of grease or excessive grease can
harm a bearing.

Need more information?

We have a number of resources to help you better understand what Plant Empowered Reliability Improvement (PERI) means to you and
your plant, and how iLearnReliability will provide you a clear roadmap to reliability improvement success. If we have not already sent you
any of the following pieces, please email or call us and we will be happy to provide them to you.

Plant Services Special Report; Common-sense Reliability Improvement Creating a Learning, Bridge-Building, Precision
Maintenance Organization
iLearnReliability lead brochure
iLearnReliability Training Module Sampler e-Presentation
Why you need iLearnReliability overview presentation by Jason Tranter, Mobius Institute Founder and Managing Director

Contact us today!
Contact us today to learn more or to get started with your iLearnReliability subscription. Call us toll free in the US & Canada at (877) 550-
3400. Call us outside of North America at (+1) 615-216-4811 (GMT - 5). Or you can send us an email at [email protected]. We
look forward to hearing from you.

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DISTANCE LEARNING COURSES

Mobius Institute offers web-based, self-paced ISO Category I, II, III & IV (Part 1) Vibration Analyst training courses. Vibration Analyst
certification is provided through Mobius Institute Board of Certification (MIBoC) and is accredited to ISO 18436-1 and ISO 18436-2. Machine
Balancing and Alignment courses are also available.

PUBLIC COURSES & ON-SITE COURSES

ISO Category I, II, III, & IV Vibration Analyst training courses and accredited certification are available in over 50 countries through Mobius
Institute Authorized Training Centers (ATCs). Courses may be provided at your site though our onsite training program.

PC-BASED e-LEARNING TRAINING PRODUCTS

iLV iLearnVibration Vibration analysis training for beginner and intermediate vibration analysis.
iLA iLearnAlignment Machine coupling alignment training for vibration analysts and machinists.
iLB iLearnBalancing In-place machine dynamic balancing for vibration analysts and machinists.
iLR iLearnReliability [Enterprise], [Professional Development] and [Condition Monitoring] to help your plant achieve higher
reliability or to help individuals achieve reliability certification.

ABOUT US

Mobius Institute is a worldwide provider of asset management, reliability improvement, and condition monitoring education and certification
to industrial plant managers, reliability engineers and condition monitoring specialists. Mobius delivers training via public, in-plant and online
formats. Mobius key advantage is its extensive experience and success in teaching plant professionals and technicians since 1999, and by
offering high quality training material that includes innovative animations and simulations, which make complex topics easier to understand.
Mobius Institute Board of Certification is ISO 9001 certified and is an ISO/IEC 17024 and ISO 18436-1 accredited certification body that
provides globally recognized certification to reliability and condition monitoring professionals. Mobius Institute has offices in Australia, Belgium
and the United States, and authorized training centers in more than 50 countries. For more information, call (615) 216-4811 (GMT -5), or
email [email protected] or visit www.mobiusinstitute.com.

LEARN, LEAD, SUCCEED.

280 Myers Road, Merricks North, Victoria, 3926, AUS

Tel: (+61)3-5989-7285

North America: Post Office Box 11216, Bainbridge Island, WA 98110, USA
Tel: (+1)615-216-4811

www.MobiusInstitute.com