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Training Workshop on 
Reliability Control Program: Managing Failures and Improving
Performance
21-23 April 2026
Mines Beach Resort, Kuala Lumpur

SYNOPSIS

A Reliability Control Program (RCP) is a structured system used to monitor, analyze, and improve the reliability of equipment and operational systems. It focuses on collecting performance and failure data, identifying trends, and taking corrective actions before problems become serious or repetitive.


The main purpose of RCP is to ensure safety, consistent performance, and cost-effective maintenance. By using data and analysis, organizations can reduce unexpected failures, improve
system availability, and meet regulatory or quality requirements. RCP is widely used in high-risk and asset-intensive industries such as aviation, manufacturing, energy, and transportation, where
reliability directly affects safety, operations, and business performance.

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LEARNING OUTCOMES
1. Define reliability concepts within an RCP framework.
2. Differentiate reliability, availability, and maintainability using operational definitions with no conceptual error.
3. Identify RCP objectives aligned to safety and performance requirements.
4. Map RCP components to regulatory requirements with complete coverage.
5. Select appropriate reliability indicators for operational systems.
6. Establish performance thresholds for reliability metrics based on operational risk.
7. Collect reliability data using standardized coding with zero critical error.
8. Validate reliability data for accuracy and completeness.
9. Calculate MTBF, MTBUR, and failure rates correctly.
10. Interpret reliability trends over time with justified conclusions.
11. Analyze repeated defects to identify systemic issues.
12. Diagnose root causes using structured analysis tools.
13. Formulate corrective actions addressing root causes.
14. Monitor post-action performance to verify effectiveness.
15. Integrate RCP outputs into maintenance planning.

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COURSE OUTLINE

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Day 1: Foundations of Reliability Control


Part1: Introduction to RCP

 

  •  What is a Reliability Control Program

  •  Objectives of RCP

  •  Importance of Reliability in Operations

  •  Benefits of Structured Reliability Management

  •  Group Discussion: “What goes wrong when reliability is ignored?”


Part 2: Company, Regulatory and Authority Requirements

  • Overview of Regulatory Authorities

  • RCP Regulatory & Company Requirements

  • Compliance and Documentation

  • Q&A: “Identify the relationship of reliability with regulatory, authority or company requirements in your industry or organization?

 

Part 3: Reliability and Maintenance Economics

  • Cost of Unreliability

  • Maintenance Cost Drivers

  • Balancing Safety, Performance, and Cost

  • Group Activity: Simple costing exercise (calculate repair cost, downtime loss, safety risk) against wait till failure.

 

Part 4: Reliability Control Program Overview

  • Structure of an RCP

  • Key Components of RCP

  • Roles and Responsibilities

  • Group Activity: Build-your-own RCP (a simple model)

 

Day 2: Data, Measurement, and Analysis


Part 5: Data Collection System

  • Types of Reliability Data

  • Data Sources

  • Data Quality and Validation

  • Group Activity: Prepare maintenance records with missing data, wrong data and good data. Other groups to provide feedback the data quality.


Part 6: Performance Measurement and Reporting

  • Reliability Indicators (KPIs)

  • Trend Monitoring

  • Reporting Methods

  • Group Activity: Choose 5 KPIs for their company, create a simple monthly report and explain why those KPIs matter.

 

Part 7: Data Analysis

  • Statistical Tools for Reliability

  • Pattern Recognition

  • Root Cause Analysis

  • Case Study: Given failure history table. Identify trends and repeating failures. Do a simple root cause analysis using 5-Why.

 

Day 3: Control, Actions, and Governance

 

Part 8: Evaluating Corrective Actions

  • Identifying Improvement Actions

  • Risk Assessment of Actions

  • Monitoring Effectiveness

  • Group Activity: Case: Repeated component failure. Groups propose corrective actions, rate risk and method of monitoring.

 

Part 9: Reliability Control Board / Maintenance Review Board

  • Purpose of the Control Board / Review Board

  • Board Structure

  • Decision Making Process

  • Roleplay: Reliability Control Board Meeting. Assign roles, discuss a failure case, make decisions and record action.

 

Part 10: RCP Tools and Software

  • RCP Software Overview

  • Practical Use of Tools

  • Case Studies

  • Group Activity: Demo or mock system using Excel.

  • Group reflection: “How software helps RCP”.

WHO SHOULD ATTEND

Department: Engineering, technical, maintenance, planning, fleet/asset management
Position: HOD, engineer, supervisor, technical support, maintenance planner, technician, safety officers, asset managers

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FEE AND REGISTRATION

RM1,200/pax (inclusive of training materials in hardcopy, lunch and refreshments).

Click the following link for registration:

Trainer profile

Uphallee Maniam is a technical trainer and former technical services manager specializing in technical, reliability, safety, and audit compliance. With experience in aviation and engineering environments, he delivers practical, standards-based training for technical teams, compliance officers, and operational leaders.

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