How to be ‘certified’ in Weibull Analysis (and Why It Matters)

Christopher Jackson
Sep 3
7 min read

Updated: Sep 23

In the world of reliability engineering, few tools are as powerful - or as misunderstood - as Weibull analysis. It is a statistical tool, which can turn people ‘off’ straight away, as we can immediately leap to a list of equations and tables of numbers that we need to memorize and embrace. But Weibull analysis is different. You actually don’t need equations.

Check out the chart below, which is called a ‘Weibull plot.’ The different shapes and colours representing the failures of different components can tell us so many things without having to evaluate a single equation.

Money falling into the ocean. — A Sample of a Chart Plotted using Weibull Analysis

For example, the curves and bend on the chart above shows that for a mining truck engine assembly, a switching valve is failing due to installation issues or defects (which a quick review of prescribed steps can identify), another component is failing from randomly occurring external stresses (that additional caging and protection could eliminate), and that the component that ‘limits’ the life of the engine is a small scavenge pump that is wearing out (which could be simply and cheaply replaced with a more robust pump).

You can find all this out if you just know what to look for. And now you know some simple steps you can undertake to dramatically (and cheaply) improve reliability.

But if you do want to take the next step and start dealing with numbers, you can predict failure rates, optimize maintenance schedules, and make data-driven decisions, even with limited failure data. Yet, despite its versatility, many professionals lack formal training in Weibull analysis, limiting their ability to fully leverage its benefits.

At Acuitas Reliability, we believe that mastering Weibull analysis isn't just a technical or professional development milestone - it's a strategic advantage. In this post, we'll explore why qualifying in Weibull analysis is essential and how you can achieve it.

Why Weibull Analysis Matters

Weibull analysis is a cornerstone of reliability engineering. The reason is that the underlying ‘Weibull distribution,’ upon which it is based, models particular ways things fail by understanding how long it takes for the last residual part of a component to ‘break’ when it is under stress. So, regardless of whether the component fails due to fatigue, wear, corrosion, or even infant mortality, the Weibull distribution does a very good job of modelling how each happens.

This means that Weibull analysis can offer insights into product lifecycles, failure modes, and maintenance needs. Unlike other statistical methods, Weibull analysis can handle small data sets and adapt to the various ways things fail, making it invaluable for early-stage product assessments and ongoing reliability monitoring.

But let’s get into a few more key benefits of Weibull analysis:

Preventive Maintenance. Weibull analysis can help us find the first signs of a product wearing out, helping us work out how often to conduct preventive maintenance (PM) correctly. If we make our PM intervals too short, we waste time and introduce lots of maintenance-induced failures. If our intervals are too long, the failures we are trying to prevent occur anyway. This means we can reduce downtime and maintenance costs in an informed way.

Warranty Optimization. You want to offer a long warranty period to attract more customers and dominate your competitors. But you don’t want your warranty period to be so long that you are paying for so many failures that you lose your profit margin. Weibull analysis can help you work out how long your warranty period should be.

Failure Mode Identification. Remember those different components failing on our mining truck engine in that ‘Weibull plot’ we talked about earlier? Understanding how they fail is very important for working out what to do about them. Weibull analysis shows you which products are wearing in or experiencing infant mortality. These are the ones where you need to look for defects or pre-existing damage before they are used. Those that wear out are the ones that can be targeted for PM, predictive maintenance, or even upgraded to improve the useful life of the system.

Resource Allocation. Weibull analysis helps you work out which components to address and what to do. This helps you make informed decisions about where to focus reliability efforts and investments (in other words … you don’t waste time furiously fixing the wrong problem).

By understanding and applying Weibull analysis, engineers can transform reactive maintenance strategies into proactive reliability programs.

The top of a submarine vessel sticking out of the ocean, with a sunset in the background.

The Value of Becoming Certified to do Weibull Analysis

There is a lot of information out there teaching us how to change the sealing valve in a toilet, planting flowers in your garden, learning a new language, and so on. There is a fair bit of free (or at least, widely available) Weibull analysis content. But while self-study can provide a basic understanding of Weibull analysis, formal training and certification offer several distinct advantages.

First, there is the Structured Learning. Formal courses that offer qualification and certification programs provide a comprehensive curriculum that covers both fundamental concepts and advanced applications. When you try to learn by yourself, you don’t know which bits are the most important to learn, which bits that people say you need to learn (but don’t need to), and perhaps most importantly, when you have learned all that you actually need for your specific reliability engineering requirements.

Then there is the Hands-On Experience. Many courses include practical exercises using industry-standard software, ensuring you can apply what you've learned. But even then, you need to have an understanding of which software works for you (and not). When you try to learn by yourself, you might come across software promotional videos masquerading as lessons.

Gaining qualifications and certification gives you Credibility. These demonstrate expertise to employers, clients, and peers, enhancing your professional reputation. One of the biggest problems reliability engineers have is being believed. Showing your certifications and qualifications really help.

Career Advancement is something that being a certified ‘Weibull analysis master’ can really help. Certified professionals often have better job prospects and opportunities for advancement in reliability engineering roles. In any industry where achieving reliability quickly and cheaply is important (which would be every industry), certification in Weibull analysis signals a commitment to excellence.

Choosing the Right Weibull Analysis Certification Program

So let’s say that you have chosen to become certified in ‘Weibull analysis’ and start looking for a program. Every course or certification provider will tell you that their program is the best. So consider the following factors:

Understanding the problems you want to solve. While Weibull analysis can be helpful in a very generic sense, understanding the problem (or types of problems) you want to be able to use Weibull analysis to help you solve is very important. If you can’t see how Weibull analysis can help solve your problem, then you are probably looking at the wrong course!

Curriculum Depth. Ensure the course covers both basic and advanced topics relevant to your role. If the course outline focuses on mastering statistical concepts like maximum likelihood estimation, the Fisher information matrix approach to confidence, and regression on Y versus X – without explaining how mastering these things will help you actually make better decisions – find another course!

Instructor Expertise. Look for programs taught by experienced professionals with practical industry knowledge. You don’t want instructors who have spent their entire careers in academia. You also don’t want instructors who haven’t spent any time mastering their own statistical analysis expertise.

Software (pros and cons). Many Weibull Analysis software packages are extremely expensive. Some courses actually focus on teaching students how to use their software, which is not the same as learning how to do Weibull analysis. Once you have completed their course, you are essentially locked into paying for their software forever. Other organizations can make the distinction between the two. Some programs teach you how to become proficient in Weibull analysis without software … meaning you can pick and choose your approach to off-the-shelf tools afterwards.

How to Get Certified

Several reputable organizations offer Weibull analysis certification programs. These courses vary in duration, format, and depth, allowing you to choose one that fits your needs and schedule. So why should you choose Acuitas’ Weibull Analysis Course?

Our course is designed to teach students how to master Weibull analysis and conduct sophisticated analyses confidently. What we do differently is help students ‘understand the story’ of the data that is illustrated before them. Other courses teach the equations and the criteria for making certain conclusions. This doesn’t work in practice as this means you have to commit to memory equations, numbers, parameters and so on. What really works long term is the ability to visualize and recognize patterns. The Weibull plot that we showed above is a great example of how very important asset management decisions can be made based on knowing what the different shapes the data traces out mean.

In other words, we teach you how to ‘see’ the different ways things fail.

Once you understand this, the equations and numbers that are important to even more useful decisions become really easy to remember. Our curriculum covers improving reliability metrics, understanding Weibull distributions, and interpreting data to add value to your organization. When you have completed our course, you will be equipped with the skills to perform advanced Weibull analyses and contribute meaningfully to reliability engineering efforts.

But perhaps best of all, our course includes a free Weibull Analysis plotting tool (usable in Excel) so students can start practicing what they’ve learnt without having to worry about any additional costs. You aren’t on the hook for software licensing forever. Nor are you left without any tool to help you out in the future.

Our 24-hour virtual course led by Dr. Chris Jackson, provides flexibility for professionals worldwide. The course focuses on practical applications of Weibull analysis in reliability engineering.

Where to now?

Become qualified or certified in Weibull analysis is more than a professional milestone - it's a strategic investment in your career and your organization's success. By mastering this powerful tool, you can lead initiatives that reduce failures, optimize maintenance, and improve product reliability.

At Acuitas Reliability, we're committed to empowering engineers with the knowledge and skills needed to excel in reliability engineering. Investing in the right certification program can significantly enhance your skills and career prospects in reliability engineering.

Our Weibull Analysis Course is designed to provide comprehensive training that translates into real-world results.

Ready to take the next step in your professional development? Our Weibull Analysis Course is open for registration. Learn more about our Weibull Analysis Course and start your journey toward certification today.