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Workshop STREAM 11 Reliability Engineering Excellence

Reliability Engineering Excellence

Reliable Plant is Safe & COST-EFFECTIVE Plant

Lecturer: Hosny al Sayed


Reliability is a cornerstone of any maintenance process.  Get it right and you can enjoy good safety performance, low running costs and a sustainably high production level at the right quality.  Reliable plants are usually safer and cite a higher level of morale.  Lose control of reliability & operation become less predictable, chaotic and life gets very difficult – maintenance planning becomes much harder, production targets will be missed and operations become more chaotic, HSE can suffer and everything feels difficult to control.

Reliability is not the responsibility of maintenance alone and outstanding performance can only be achieved with a strategy that includes operations, design, materials and contractors.  This course is based upon Rex Pro Model of Excellence for bringing all these considerations together as one to achieve pace-setter standards.

Many Originations are facing competition and decreasing margins. If you really want to compete you must understand how to make your work and operating processes more efficient and effective. Your equipment must be reliable and safe to operate. It must be ready to operate at peak capacity at short notice and production output must be at high quality rate. This course is aimed to create leaders in Maintenance, Reliability & Physical Asset Management sectors who are recognized all over the world.

This is a highly practical course that includes the latest thinking in reliability improvement, how to gain maximum benefit for minimum effort and how to develop bespoke reliability strategies that will integrate effectively with other campaigns.  This will include methods and tools as well as the Rex Pro Model of Excellence to add structure and enable participants to break this complex subject into smaller, more understandable parts.

This Reliability Engineering Excellence (REX) Workshop will help you learn how to:

     Latest best practices in maintenance & reliability filed activities related to safe and effective organization performance.

     Review reliability-based asset management philosophy.

     Describe RE roles and responsibilities.

     Define the essential components of a successful reliability program

     Develop reliability programs that align with the unique needs of their business, asset and maintenance strategies

Reliability Excellence Frame Work    

     »» Essential Reliability terms & definition

     »» Maintenance & Reliability Program Elements

     »» P-F & DIPF Curve | Asset utilization

     »» Maintenance & Reliability Program Evolution

     »» Safety, Quality, and Reliability

     »» Reliable Plant is Safe & Cost Effective Plant.

     »» Process Safety & Reliability Pyramid.

     »» Reliability Function Role

     »» Failure Consequence | Cost of unreliability



Hosny al Sayed

Hosny is a 30 years extensive & proven experience professional in a wide range of industries.

An innovative, highly qualified operations, maintenance and reliability professional with broad-based experience in all aspects of industrial equipment, quality assurance, materials management, supply chain management, and reliability engineering in the fields of the Petrochemicals, Oil & Gas upstream as well mining & metal industries.                     

Hosny is a professional that possesses a proven ability to implement advanced methodologies that drive dramatic cost, quality, and productivity improvements, Intelligent Asset Management, Maintenance & Reliability Engineering processes, Operation Excellence, Lean Manufacturing, Six Sigma, inventory management, A visionary change agent with multi-plant and industry experience, proficient at developing strategic organizational direction and capable of taking organizations to new levels of performance never before achieved.

Hosny enjoys advocate plant improvement process, Reliability Excellence (Rex) & Operation Excellence (OPEX) Development & Implementation in addition to business process auditing.

As Reliability & PAM Professional, Hosny objective is focused on achieving Plant Asset Safety, Integrity, Availability and Reliability performance in line with the latest engineering standards & practices.

2019 Uptime Award is the latest Hosny’s Achievement in field of Asset Management & Maintenance Reliability

Hosny is currently Leading Digital Manufacturing & Operation (DMO) at Accenture Middle East - Industry X . Prior to his current role he worked as Mine & Refinery Reliability Manager at Ma’aden Alumina Refinery in Saudi Arabia leading the Implementation of Reliability Excellence (Rex) core operating standards. For this role Hosny was accountable for Reliability Engineering, PAM, Asset Integrity and Maintenance Planning business process to support the organization objective

Hosny has worked with Borouge petrochemical company (UAE) as Technical Service Manager, Equate Petrochemical Company (Kuwait), and General Petroleum Company (Egypt) as Maintenance Engineer.

Hosny is Mechanical Engineer since 1992, and an active member of ASQ, IAM, PMI, GSMR and approved Proctor from SMRP & WPiAM.

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