Professional Development/Certification • R&M Strategy RoadmapsDegree Programs • R&M Engineering Certificates • TechnologiesStudies/Projects/Research • Training • Benchmarking/AssessmentsBest Practices • Implementation • Change Management • MARCON

A Message from the Director

We appreciate your interest in the Reliability and Maintainability Center (RMC). Established by the University of Tennessee in 1996, the Center is a unique industry/academia partnership dedicated to improving productivity, efficiency, safety, and profitability through development and dissemination of advance reliability and maintainability technologies and management principles. The RMC creates comprehensive programs of education, research, and information sharing for industry professionals, faculty, and students, and is a valuable partner and resource to those constituent groups, leading the way in today’s improvements and tomorrow’s best practices and technologies. At the UT-Reliability and Maintainability Center we are implementing our vision to support both companies and students in getting ready for future R&M challenges and opportunities.

Dr. Klaus Blache is Director of the Reliability and Maintainability Center (College of Engineering) and Research Professor (Industrial and Systems Engineering) at the University of Tennessee. He has over 30 years of industrial experience in various areas of manufacturing. www.kblache@utk.edu

RMC Mission

The Reliability and Maintainability Center (RMC) exists to advance reliability and maintenanceeducation and practices within the academic and industrial communities. We create opportunities for member companies, students, faculty, and industry to achieve exceptional value through a comprehensive program of education, industry projects, research, and information sharing.

RMC Vision

The RMC is the trusted and premier source of people, knowledge, and research. Our students, faculty, training partners and company participants are recognized for their expertise in reliability and maintenance. Conferences, training events and education are recognized as the highest quality source of reliability and maintenance best practices information regarding, people, process and product. Included are all related physical assets (machinery, equipment and buildings), tools and technologies.

Implementation of research generates solutions that are effective at solving problems and contributing to business excellence (top quartile performance).

Areas of Expertise

The RMC deals with all aspects of reliability and maintainability, including physical-asset management; equipment reliability; predictive maintenance; and machinery condition monitoring technologies such as vibration analysis, airborne ultrasonic, infrared thermal imaging, motor testing, alignment and oil analysis.

Using a “systems thinking” approach, the RMC also focuses on reliability and maintainability strategies and techniques such as benchmarking, assessments, root-cause analysis, reliability roadmaps, reliability-centered maintenance, operator based maintenance, computerized maintenance management systems (CMMS), lean implementations, reliability modeling, Weibull analysis, and enterprise-asset management. The RMC is dedicated to becoming the premier source of qualified reliability and maintainability personnel, knowledge, and research by:

• Developing company professionals, students, and faculty who are sought after for their expertise

• Sponsoring conferences and educational initiatives that provide the highest quality source of best-practices information

• Conducting research that generates effective, applicable solutions when implemented

Membership Organization

The Reliability and Maintainability Center is a university - industry association dedicated to improving industrial productivity, efficiency, safety, quality & profitability through advanced reliability and maintenance practices, technologies and management principles. The RMC is supported, in part, by over 65 member companies from all types of industries. We focus on R&M related initiatives that improve key performance indicators of our member companies. Member companies get discounts to RMC, R&M trained students, interns, and are invited to participate in bi-annual two- day meetings of R&M presentations and discussions.

Programs and Initiatives

The RMC offers programs in four primary areas:

Education & Professional Development – The RMC, in conjunction with the College of Engineering, offers a wide spectrum of educational opportunities.

Our undergraduate offerings are unique among US universities and include a Reliability and Maintainability Engineering minor and R&M internships, all within the BS degree curricula. The Graduate Certificate in Reliability and Maintainability Engineering and the Master’s Degree in Reliability and Maintainability Engineering (delivered on-campus and through distance learning) are administered through UT’s Graduate and International Admissions School: http://graduateadmissions.utk.edu.

Our Professional Development offerings provide a University sanctioned certification in (RMIC®)Reliability and Maintainability Engineering Implementation (non-degree), through a combination of courses from the RMC and selected industry training partners, and a results-focused project. Further details and specific classes can be found at www.RMC.utk.edu. Additionally, several short courses and seminars are available on demand in the Knoxville area or at company sites.

Research and Technology Assessment – The RMC conducts research and technology assessment projects recommended by its industrial affiliates and supported by its members and/or third party funding. Faculty and students conduct projects utilizing laboratories and other resources at the

University of Tennessee and national research facilities such as Oak Ridge National Laboratory (ORNL).

Information Sharing – The RMC holds regular meetings for its member companies and organizations to share “best practices” and other information. The Center also sponsors MARCON (Maintenance And Reliability Conference), an annual public forum for nationally and internationally recognized specialists to exchange information on new methods and practical applications of advance techniques in the maintenance and reliability field. Business Support and Alliances – The RMC seeks to support businesses and build alliances among the

member companies and organizations, partnering institutions, and the university. The center provides meeting and networking opportunities, facilitates various technical activities and benchmarking opportunities, provides introduction into other parts of the university and larger community, and offers other appropriate support functions.

Center Resources

In addition to the administrative staff and RMC consultants, the RMC draws on faculty and students from all departments within the UT College of Engineering, plus professionals from member companies and affiliates as needed. This flexibility and capability provides the RMC with a significant number of resources with very diverse interests available to lead or respond to almost any opportunity.

When Preparing for Your R&M Journey.

Ask yourself…

What must you learn to perform your job better?

What capabilities will give you a competitive advantage?

What new R&M knowledge and skills do you want to learn?

What do you want to be able to do with the new knowledge and skills?

The UT-RMC model is focused on providing both knowledge and experience. The key is knowing both what to do and how (actually performing the skills or tasks).

“It’s not only what you know, but what you do with that knowledge that’s important. It’s the ability to analyze, problem solve, apply and implement that brings value to the R&M profession.” Dr. Klaus Blache

Professional Development

The Reliability and Maintainability Center (RMC) offers a full range of professional development in R&M. There is enough flexibility to allow participants to attain a general reliability and maintainability knowledge base or get very specific in a field of application interest. Over twenty five courses are offered annually by the RMC and over 100 courses are offered through RMC Training Partners for the tradional (RMIC®).

Example of RMC Classes available:

• Overview of Modern Reliability and Maintainability Concepts (R&M Boot Camp)• PM Optimization and FMEA/RCM• The Factory-Practical R&M Improvements• Maintenance Planning and Scheduling• Fundamentals of R&M and Best Practices (with optional CMRP exam)• Maintenance Leadership and Supervision• Weibull Analysis• Spare Parts Best Practices• Predictive Maintenance Technologies Overview• Essential Craft Skills 1-Precision Maintenance, Assembly & Installation• Essential Reliable Mfg. Skills BootCamp• R&M Leadership Boot Camp• R&M Data Center Boot Camp• R&M Best Practices Self Assessment Process

Online Classes/Training:

• Eruditio - iBL Skills Building• Mobius - Predictive Technologies• SPKH - Spare Parts Management

For more info: http://rmc.utk.edu/professional-development/

An online certification, Skill Building focused, is offered in partnership with Eruditio inspired Blended Learning (iBL). It starts with a one week kick-off to solidify the basics, then 52 e-learning modules, along with a progressive project to highlight module learning. www.eruditiollc.com/applied-learning/

The e-learning curriculum is organized into the major areas of:

• Asset Health Management• Work Execution Management Overview• Developing Effective Work Procedures• Reliability Centered Maintenance• Root Cause Analysis • Reliability Engineering• Materials Management Optimization

R&M Implementation Certification(RMIC )

• Select 3 Courses from 30 training events (UT-RMC)• R&M Boot Camp (required)• + 2 others

• Select 3 Courses from RMC Training Partners• Over 100 course selections• 1 can be a predictive technology certification

• Certifying Project (3-6 month) that deliversmeasurable results (agreed to by company,employee & RMC)

• Put RMIC on your business card

RMIC

RCM - Leadership - PdM Technologies - RCA/Analytics - Precision MaintenanceBuild Your Personalized Certification Track (Leadership, Engineer or Trade/Technician)

For more info contact:Dr. Klaus Blachekblache@utk.edu(865) 974-9628

R&M Strategy Road-Maps Degree Programs R&M Engineering/Certification Benchmarking/Assessments Best Practices/Implementation Studies/Projects/Research Technologies Change Management

®

®

As shown in Figure , those enrolled in the R&M Implementation Certification (RMIC) take a minimum of six courses and complete an implementation project. Up to three courses can be taken from training partners to enable specific focus on desired areas. Go to www.rmc.utk.edu/certificate/ for a current list of course offerings.

Essential Reliable Mfg. Skills/Training

The purpose of the Essential Reliable Manufacturing® Skills (ERMS) series is to prepare those in a reliability leadership position with the practical knowledge and the knowhow to effectively lead their respective organizations to make the reliability improvements needed to effectively meet the site’s business objectives. This series delivers both the what and the how (with enabling skills) to achieve competitive advantage. The ERMS series (Bootcamp + 9 courses) has been carefully designed for anyone who has a role in plant floor reliability including reliability leaders, production and maintenance leaders, managers, supervisors, engineers, and trades/technicians.

(Course 1) ERMS BootcampIntroduction to Reliable Manufacturing provides an overview of the following subjects • Asset Strategy Development • Condition Monitoring • Asset Operation and Troubleshooting • Root Cause Problem Elimination • Implementing Reliable Manufacturing

(Course 2) Foundational Elements

(Course 3) Condition Monitoring Techniques

(Course 4) Machinery Assembly and Installation

(Course 5) Component Failures, Identify and Control

(Course 6) Vibration Analysis and Electrical Condition Monitoring

(Course 7) Pumps and Pump Systems

(Course 8) Asset Operation and Troubleshooting

(Course 9) Root Cause Problem Elimination

(Course 10) Implementing Reliable Manufacturing

More details are available on all of the ERMS courses at http://www.reliabilitysolutions.net/. Go to http://rmc.utk.edu/ for a course schedule.

All projects have mentoring/coaching to guide how what has been learned can be applied at work with measurable results. Upon completion of the RMIC curriculum and project, company participants will be granted a University-sanctioned Certification in Reliability & Maintainability Implementation from the University of Tennessee-RMC.

UT-RMC Graduates

Victor & Tricia Foster, both RMC graduates with B.S. Degrees in Mechanical Engineering, work at Lucite International, as reliability engineers.

Victor States,

“We got into reliability through the RMC summer internship program. We participated in two internships at DuPont. My experience at the Corian® and sodium cyanide facilities allowed me to be a competitive candidate as I interviewed for a full-time job. Ultimately, my wife and I decided to take jobs as maintenance reliability engineers with Dow Chemical. We chose to continue with reliability because we saw it as a growing field and something where we could bring skills that few others could.

“Our next jobs took us to the former RockTenn (currently WestRock) paper mill in Panama City, FL, where my experience and knowledge of reliability allowed me to be promoted to a mechanical reliability leader for the North American division. I credit my knowledge and training from the RMC for allowing me to progress so quickly to a position of advising mills across the continent on how to implement reliability best practices, since I was only out of college for three years.

“When we wanted to move home to Memphis to start a family, I was fortunate to find a position as a senior reliability engineer for Cargill, immediately. I worked there until the plant closed, leading the site’s reliability engineers and predictive maintenance services. Now, I continue to work in reliability at Lucite International. I chose a career in reliability because I realized that reliability is a high priority in industry, but many people lack the skills and knowledge to implement it. This gave me a competitive advantage in the job straight out of college and through my career.”

Tricia says, “I have worked both in reliability and production roles. I really enjoy reliability as it provides a solid basis for evaluating decisions based on long-term cost of ownership. The problem-solving and critical thinking skills taught in the reliability field are appropriate and appreciated equally in reliability production, and project engineering roles. “The University of Tennessee RMC has an exceptional program. I have had the pleasant experience of supervising a high-quality RMC intern, who was much better prepared than other interns and even college graduates. I personally graduated college much more prepared for work in industry than many of my coworkers from other top-tier universities. Almost a decade later, the fundamental background in R&M that I gained while in school is still relevant. I have referenced by materials from my R&M courses more than any other course material. It is outstanding that the RMC has led the country in developing the course work that merges industry and academia. I fully encourage every engineer to explore the core concepts of reliability engineering, even if they are not certain that reliability will be their specialty; the reliability concepts are broadly applicable and highly useful.”

Degree Programs

Earn RME Minor with a B.S. Degree in Engineering.The Minor in RME requires five courses in the area of reliability and maintainability (two required and three electives) and must be achieved within the framework of a bachelor of science degree. An example would be a B.S. in Mechanical Engineering with a Minor in Reliability and Maintainability Engineering. The RME Minor appears on the student’s official transcript.

M.S. Degree in RME

The College of Engineering at the University of Tennessee and the Department of Statistics, Operations and Management Science have teamed to offer an interdepartmental master of science degree in Reliability and Maintainability Engineering. The M.S. program consists of 30 hours of graduate work in RME, with a concentration in one of the traditional engineering academic departments - chemical, industrial, mechanical, nuclear, or electrical and computer engineering, etc. The program can be completed on campus or through real-time and interactive distance delivery.

RME Certificate (for University enrolled students)

The graduate certificate is an interdepartmental initiative designed for students who wish to pursue careers in Reliability and Maintainability Engineering. It is also suitable for professionals and managers currently working in the field looking to improve

their knowledge and skills. The program consists of four graduate engineering courses, two required courses and two elective courses. The two required courses introduce the student to the fundamentals of maintenance engineering and reliability engineering. The two elective courses are selected from a list of RME-related courses that currently includes courses in five traditional engineering disciplines.

For more information on academic opportunities go to www.rmc.utk.edu/

Summer Student Internships

Students work on projects during a 13-week session with deliverable results. Examples of assignments in companies across North America are:

• CMMS system improvements at Harley Davidson, Wisconsin

• Infrared analysis of electronic parts (product) at Schlumberger, Colorado

• Reliability and maintenance improvements on facility practices at Oak Ridge National Lab Supercomputer Complex, Tennessee

• Facility maintenance improvements at Sandia National Laboratories, New Mexico

• System redesign of electronic testing equipment at Schlumberger, Louisiana

• Developed asset risk assessments for critical equipment at Novelis, Georgia

• Analysis of leaks and moisture related damage

The University of Tennessee Reliability and Maintainability

Engineering & Center

College of Engineering (industrial / mechanical / chemical /

nuclear / electrical and computer)

Reliability and Maintainability Center and Labs

Degree • RME Undergraduate Minor

with Bachelor in RME orMaster in RME

Professional Development • RMIC® Certification

• Implementation• Skill Building• Essential Reliable

Mfg. Skills RMC Member Companies

• MARCON Conference• R&M Roadmaps, Assessments• 2 member only mini-conferences• Research projects and studies• Training

Reliability and Maintainability Practitioners (with knowledge and experience)

for Engineers

RMC summer student Internships (13 weeks)

for Technicians/Skilled Trades, Engineers and Managers (customized to outcome needs)

The Figure is an overview schematic of the current program that offers a R&M learning path for trades/technicians, students, engineers and managers. The focus is on both knowledge and experience, resulting in practioners/problem solvers.

on helicopter parts, Redstone Arsenal (U.S Army), Alabama

• Performed FMEA’s and improvements on the slitter saw system at Owens Corning, Ohio

• Developed troubleshooting software for operator consoles at DuPont, Virginia

• Improved equipment lubrication program at Nissan, Smyrna

• RCM analysis of chiller buildings, B&W Y-12 (National Security Complex), Tennessee

• Determined new product control and specification limits to be used for machine set-up at RockTenn, Florida

• Mobile equipment upgrades and criticality assessments, Alcoa, South Carolina

• Developed detailed reliability processes for RCA, Criticality Assessment, RCM, and Risk Based Inspection at SABIC Innovative Plastics, Indiana

• Evaluated the accuracy of manufacturing targets at Schlumberger, Texas

Here are some comments about interns from their supervisors:

“Russell exceeded the expectations of a second term summer student. His accomplishments are closely related to that of a 2nd to 3rd year full time reliability engineer.”

“Miles has been a great addition to the Sustaining team here. He has given an excellent kick-start to our efforts to start a reliability centered maintenance program, and a lot of his work will serve as a foundation for future work to build upon”.

“Patrick worked with a senior engineer to analyze the Reliability performance of several components on the AH-64 Apache helicopter system. The work he has done has been very valuable to this organization and to the U.S. Army.”

“Shanel is an excellent intern/student. She learns very quickly and she is strong technically. I was very impressed with her enthusiasm and her willingness to learn. It is my hope that our company makes her an offer of employment.”

“Ross adapts quickly and developed leadership skills that will benefit him in the future. His project made a substantial impact on the site and the operations of the equipment involved in his project”.

“Kyle has been a definite asset during his time with us. He has the ability to both work and think outside the box, offer valid suggestions and present excellent ideas to our team and team’s objectives.”

“Chris was an excellent addition to our group of maintenance engineers this summer. He was enthusiastic about learning RCM principles and applying them to his summer project. Chris would be an asset to any engineering program and we hope that he is interested in returning next summer.”

During the first week of their first Summer Internship, the students attend an intense (one week on campus) R&M Training Program with representatives from numerous companies (typically 70 to 100 attendees).

The RMC regularly puts students into Summer Internships in over half of the United States. Some of the companies and organizations that have used UT-RMC summer interns are Alcoa, Amazon, Bayer, Boardwalk Pipeline Partners, Domtar, Dow, DuPont, Energizer, Fluor Global, Harley Davidson, Jacobs, Keurig, Nissan, NiSource, Novelis, Oak Ridge National Lab, Setech, Owens Corning, Redstone Arsenal, SABIC, Schlumberger, Y-12 National Security Complex and Sandia National Lab.

At the 2013 MARCON Conference, during his keynote address, Mark Corrigan, V.P. Operations Integrity, Schlumberger, mentioned to the capacity-filled audience that “one of the reasons that we are involved with the University of Tennessee and the Reliability & Maintainability Center is because it’s the premier place for recruiting R&M Engineers”. Mark is based in Paris, France.

Some of the companies are involved with RMC professional development, some are sponsoring their employees for RME degrees, and some are involved with company-specific projects with the RMC and students.

Figure Above: Company participants and summer interns atR&M Boot Camp.

UT-RMC Graduate

Brad Hill, MS-R&M Engineering works at Schlumberger as Reliability & Maintainability Metier Manager

“I started working with Schlumberger Technology Corporation as a Field Engineer in 2003 after completing a bachelor’s degree in Electrical Engineering. After several years working in field operations and several more years in human resources, I took the opportunity to work part-time as a Maintainability Engineer with Schlumberger while also attending the University of Tennessee to get a Master’s degree in Reliability and Maintainability Engineering (RME). Although I entered the program through the Electrical Engineering department, my coursework was mainly through other departments. The flexibility of the program allowed me to continue working during normal business hours and take courses online in the evenings.

The RME degree helped me build a solid foundation in reliability and maintainability through coursework in statistics, reliability, maintainability, and systems engineering. For my final project, I did a recurrence analysis to get a better understanding of the reliability of a few of Schlumberger’s products. On the whole, the knowledge I gained while obtaining the degree has been incredibly valuable, as my current role requires a mix of theoretical and practical knowledge. Since completing the degree in 2012, I have been working as the Reliability & Maintainability Métier Manager at Schlumberger, where I am responsible for ensuring that reliability and maintainability are incorporated into product design.

I chose RME as the next step for my career, because it seemed clear to me that product reliability is playing a more and more important role in every company’s future. With increases in both product complexity and the potential cost of failure, it is even more important today than in the past that we strive to make our equipment more reliable. In the photo, I am next to a chamber where we are performing a Highly Accelerated Life Test (HALT) to try to understand the operating margins and limits of our designs. Ultimately, we want to know how our design will react to various environmental stresses, at what point in its life it might fail, and what we need to improve to prevent failure.

One of the hats I continue to wear with Schlumberger is that of the recruiter. From the time spent as an actual recruiter to my current role, I have helped the company recruit many new employees and interns. Of these interns, I have found that the RMC has done an excellent job of preparing students for roles in industry. Through a combination of the coursework required for the minor in RME, the hands-on maintainability lab, the week-long boot camp, and summer internships, I feel that all engineering interns and students coming out of the RMC are well ahead of their peers that haven’t had these opportunities.

Overall, the RME program at the University of Tennessee and the RMC has made a large difference in my career, and I can see the difference it is making for the success of others.

Figure above: The Factory- A Hands-On Maintainability Lab. Other RMC labs are focused on Spare Parts Best Practices ( includes identification of Counterfeit Parts), Predictive Technologies andReliability Data Analysis.

The course offerings cover many of the interests and needs of your workforce, (skilled trades/technicians, engineers and managers working in R&M). Of course, this list is not all inclusive. There are many types of courses offered by each of the RMC Training Partners. Persons from various companies and levels end up in most of the courses together, providing a good mix of interaction.

Learn how to use R&M as a competitive advantage. Go beyond the basics to understand key enablers, continuous improvement, working on what matters, R&M strategic planning and developing your roadmap.

June 26 - 29, 2017Bloomington, MN

By Mall of America®

Select UT-RMC Facts and Initiatives

RMC Capabilities/Resources to Leverage as required.

• There are over 100 state-of-the-art laboratories in the College of Engineering.

• Perform reliability modeling, Weibull analysis and R&M analytics.

• The RMC integrates across eight Engineering Departments (Biosystems Engineering, Chemical & Biomolecular Engineering, Civil & Environmental Engineering, Electrical Engineering & Computer Science, Industrial & Systems Engineering, Material Science & Engineering, Mechanical, Aerospace and Biomedical Engineering, and Nuclear Engineering) as needed.

• RME is the largest minor in the College of Engineering

• Undergraduate and Graduate students, faculty and training partner companies can be used to assist in projects/research.

• RMC is focused on delivering bottom-line results.

• Six metric areas to best practices initiative to understand top quartile metrics by industry type.

• Provides strategic R&M direction to companies.

• Perform research projects and special studies for companies.

• Develop R&M training plans for companies, Perform related training (public and in-house).

• RMC develops project teams to deliver results.

Ongoing benchmarking, studies and research on R&M best practices and top quartile performance.

UT-RMC Graduate

David Freestate, B.S. degree in electrical engineering, works at the Electric Power Research Institute as a project engineer. Picture is at ORNL Supercomputer Complex during an earlier internship.

“I discovered UT’s Reliability and Maintainability Center during my junior year in college. Based on my prior experience as a student co-op with Denso Manufacturing, I found that the reliability and maintainability field offered practical solutions for real-world concerns within the manufacturing environment. It was exciting to learn about the work that was being done to minimize disruptions caused by equipment failures and other complications, and to even predict such failures before they occurred.

Through the RMC, I was offered an opportunity to intern at Oak Ridge National Laboratory’s supercomputer facility, where I contributed to improving the reliability of the supercomputers’ electric and cooling infrastructure. In so doing, we reviewed existing maintenance practices and worked to develop proactive measures in line with the latest reliability and maintainability research to aid the robustness and resiliency of systems. It was thrilling to work with ORNL’s Titan supercomputer, the fastest in the world at the time, and the insights I gained from my experience at ORNL and from RMC’s training have stayed with me, developing me into a more well-rounded engineer.

After graduation, I became an electrical design engineer with Denso Manufacturing, where I designed the hardware and software for new machines in the manufacture of automobile components, as well as improving the productivity of existing machines. My knowledge of reliability practices offered an added dimension, allowing me to view the implications of design considerations from multiple perspectives. I recently accepted a position as a project engineer with Electric Power Research Institute, where I support research and analysis of distributed renewable energy resources, mainly in the arena of photovoltaic systems. One aspect of my job is evaluating the performance of system components; since the dependability of such components is a primary concern in the industry, I look forward to exploring how reliability and maintainability practices can improve the efficiency of the next generation of renewable energy resources.

I’m grateful for the opportunity to have worked with RMC, as my participation in the program not only expanded my employment prospects, but even more importantly, stimulated my imagination to envision how existing systems could be optimized to benefit society.”