Training Certificate

Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees.

Course Introduction

The highly interactive Root Cause Failure Analysis program addresses a modern approach to problem solving in maintenance management. The program is based on some of the most recent research in the field. Participants will be enabled to improve the performance of their operation with practical, down-to-earth techniques that are based on first principles.

Course Objective

Provide the knowledge and skills necessary to facilitate and understand how to maximize the result of your RCA program.

Applying ROOT CAUSE ANALYSIS to solve all types of problems, you can investigate errors, defects, failures, losses, outages and incidents in a wide variety of industries.

The course is designed to enable the candidate to work out an investigation and document the root cause of all the problems relating to equipment and human error and equipment failure that results in loss of productivity, accident and damage.

Suitable For

This program is designed for Supervisors, Team Leaders, Engineers and Managers in Maintenance, Engineering and Production from all industries.

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work & Practical Exercises
• 20% Videos & General Discussions

Course Content

Day 1

• Failure of Machines and Inspection Based Failure Analysis

Failure analysis tools

Failure Mode & Effects Analysis

Root Cause Analysis

•  Causes of Machinery Failure 

Industrial failure

Introduction

Wear mechanisms, fatigue, fretting, and corrosion and electrolytic.

Equipment, failure and maintenance data

Causes and implication

Hazards

Thermal and chemical stability data and hazardous effects of inadvertent mixing of different material

Day 2

General principles of root cause analysis

General process for performing and documenting an RCA-based Corrective Action

1. Define the problem.
2. Gather data/evidence.
3. Ask why and identify the true root cause associated with the defined problem.
4. Identify corrective action(s) that will prevent recurrence of the problem (your 100 year fix).
5. Identify effective solutions that prevent recurrence, are within your control, meet your goals and objectives and do not cause other problems.
6. Implement the recommendations.
7. Observe the recommended solutions to ensure effectiveness.
8. Variability Reduction methodology for problem solving and problem avoidance.

Day 3

Root cause analysis techniques

• Desired.
• Failure mode and effects analysis
• Fault tree analysis
• 5 Whys
• Ishikawa diagram, also known as the fishbone diagram or cause-and-effect diagram. Pareto analysis
• RPR Problem Diagnosis –

Day 4

Basic elements of root cause

• Materials
  • Defective raw material
  • Wrong type for job
  • Lack of raw material
• Machine / Equipment
  • Incorrect tool selection
  • Poor maintenance or design
  • Poor equipment or tool placement
  • Defective equipment or tool
• Environment
  • Orderly workplace
  • Job design or layout of work
  • Surfaces poorly maintained
  • Physical demands of the task
  • Forces of nature
• Management
  • No or poor management involvement
  • Inattention to task
  • Task hazards not guarded properly
  • Other (horseplay, inattention....)
  • Stress demands
  • Lack of Process
• Methods
  • No or poor procedures
  • Practices are not the same as written procedures
  • Poor communication
• Management system
  • Training or education lacking
  • Poor employee involvement
  • Poor recognition of hazard
  • Previously identified hazards were not eliminated

Day 5

Condition Based Maintenance

Data collection

Assessment

Correction action

Inform

Follow up

Root cause failure

Failure modes and effects analysis

Failure mode, effects, and criticality analysis (FMECA)

How Root Cause Analysis Works