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Phase 2 - Effective Reliability Rounds (EOC2)

Operator-Driven Rounds (EOC2)

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Training 3 - Operators EOC-2000

Operator-Driven Rounds (EOC2)

Train operators as the first line of defense — building inspection habits and early failure detection to improve uptime and support predictable production.

2 Days Duration
On-Site Location
Hands-On Format
10-15 Recommended Participants
Overview

What this course is about

Operator Driven Reliability (ODR) trains operators to act as the first line of defense against equipment failure through structured inspections and proactive asset care. The program builds strong inspection habits, early failure detection skills, and reliability-focused behaviors within daily operations. Focus is on facility-common assets to improve uptime, reduce surprises, and support reliable, predictable production.

Key Topics Covered

  • Reliability Foundations
    Failure patterns, P–F Curve, & operator role in reliability
  • Sources of Machine Failure
    Misalignment, unbalance, contamination, and improper operating conditions
  • Common Machine Components
    Friction, bearings, and lubrication awareness
  • Inspection Techniques
    Practical inspections using visual, thermal, vibration, and ultrasonic tools
  • Machine-Specific Inspections
    Motors, pumps, fans, gearboxes, drives, and hydraulic systems with operator-focused inspection methods
  • Why This Training Matters

  • Moves reliability upstream
  • Maximizes existing workforce capability
  • Improves inspection quality & consistency
  • Delivers immediate financial impact
  • Who Should Attend
    • Equipment & Line Operators
    • Lead operators and shift supervisors
    • Leaders responsible for reliability initiatives
    • Maintenance Supervisors & Planners
    • Production & Process Operators
    Typical Daily Outline

    What 2 days looks like on the floor

    Day 1
    Day 2

    Reliability Foundations & Inspection Strategy

  • Introduction, course objectives, and reliability concepts
  • Asset function, failure vs. breakdown, and inspection purpose
  • Age-related vs. random failures and reliable manufacturing principles
  • Classroom exercises on inspection and failure mode awareness
  • Introduction to Asset Strategy Development (ASD) and operating context
  • P–F Curve, inspection frequency, and failure prioritization
  • Review of current inspections and facility-common equipment
  • Exercises analyzing inspection effectiveness and controlled failure modes
  • Asset Care Strategy & Field Application

  • Review of key concepts& ASD group exercise
  • Developing condition-based inspection and asset care strategies
  • Field inspections of selected facility assets
  • Identification of improvement opportunities and failure risks
  • Development of operator inspection tasks and care strategies
  • Work request best practices, final review, and course wrap-up
  • Upon successful completion, participants will be capable of:

    Understand how machines fail and the difference between process and equipment reliability

    Perform structured inspections using sensory checks and basic measurement tools

    Use operator-level tools to quantify abnormal conditions and identify early failure indicators

    Apply preventive actions and integrate reliability inspections into daily routines to reduce downtime

    Learn more about the full training program

    Select any course below to explore its full details, objectives, and schedule.

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