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Diagnosis of Engineering Failures

a systematic investigation to determine the root cause of a component or system breakdown to prevent recurrence, address legal issues, and improve future designs

Session Details

Jubail

USD 4,250.00

excl. VAT
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Overview

  • The Diagnosis of Engineering Failures & Mechanical Component Failure Analysis training course is designed to keep participants informed about the latest engineering trends, methods, and strategies aimed at enhancing the condition and efficiency of their operational processes.

  • This practical training will provide you with essential foundational knowledge and skills needed to optimize the functioning, daily operations, and maintenance of the five key aspects of the Diagnosis of Engineering Failures process.

  • Participants will learn to recognize critical characteristics of failed components and the necessary corrective measures to avert future equipment failures. Supported by a comprehensive collection of failed components case studies, this course offers vital insights for technical professionals working in manufacturing environments.

  • Attendees will gain exposure to the essential competencies needed for effective problem-solving and the implementation of solutions within operational processes, especially in light of the ongoing global economic challenges. They will engage in various in-course tasks designed to bolster their problem-solving abilities, which will also function as a plan for improvement. Prioritizing correctly and taking appropriate actions significantly impacts performance.

  • This engaging Diagnosis of Engineering Failures program introduces a contemporary approach to problem-solving in maintenance and operations management. It has been established that merely possessing technical skills is insufficient to guarantee reliable operational performance, which is why this program explores alternative methodologies. Participants will be empowered to enhance their operational performance using practical, straightforward techniques grounded in fundamental principles.

Course Objectives

  1. Develop a comprehensive understanding and appreciation of the essential functional elements involved in conducting an effective Diagnosis of Engineering Failures.

  2. Assess the factors contributing to the failure and formulate conclusions regarding its causes.

  3. Discover methods to create a comprehensive resource for operational processes and support system evaluation, and determine the corrective actions needed to avert future failures.

  4. Identify the main characteristics of malfunctioning components, comprehend the fundamentals of an operational failure audit, and create your own process standard.

  5. Acquire knowledge and comprehension of the distinct leadership and motivational principles essential for the management and operation of technical processes.

  6. Acquire knowledge and comprehension of the distinct leadership and motivational principles essential for the management and operation of technical failure finding processes.

Course Methodology

  • The BK Management Team believes that learning is not only about acquiring technical skills, it is also about learning behaviors & Competencies that are desirable for work in plant operation & maintenance, critical dimensions. Our holistic teaching develops our delegates' personal effectiveness to function both as individuals and as team players.

  • The course delivery & modes of instruction will incorporate Hands-on Practical Sessions using equipment, State-of-the-Art Simulators (as required), Drawings, Case Studies, Videos, Exercises, Theory, Practical skills, and Q&A sessions.

  • To enhance learning outcomes, theory sessions will comprise classroom-based lectures that will be interspersed with interactive discussions, scenario-based, case-study, group exercises, video clips, PowerPoint slides, learners' Guide, and the application of various tools, which will be provided to help the delegates and participants of the learning objectives. With the successful implementation of the learnt skills, they are bound to enhance Individual & Organizational growth.

  • For online / Interactive Virtual sessions, the Delegate should have a stable & good Internet connection on their Laptop.

Who Should Attend

The Operations Department comprises multidisciplinary teams, including Reliability Engineering, Mechanical Static, Civil, and HVAC Maintenance Engineering, Rotating Equipment Engineering, and Maintenance Support Services. Positions available include Reliability Engineer, Lead Mechanical Static Engineer, Mechanical Static Engineer, Mechanical Static Engineer (Onshore), Condition Monitoring Engineer, Head of Rotating Equipment Engineering, Rotating Engineering Team Lead, Rotating Equipment Engineer, Rotating Equipment Engineer (Graduate), Work Preparation Engineer (Mechanical), Head of Maintenance Support Service, Materials & Spare Parts Team Lead, and Repair Works Engineer which is mandetry to gain the faluire finding and elimantion comptencies, and specific for :

  • Engineering and Technical Managers and Supervisors from various sectors

  • Maintenance Planners and Coordinators, Foremen, and Team Leaders

  • Operations and Manufacturing Managers and Supervisors

  • Plant Engineers and Process System Managers

  • Operation & Maintenance Engineers and Professionals

Course Outline

MODULE 01: Diagnosis of Engineering Failures
  • Safety Moment – Major O&G Accidents and Key Learning lessons – Learn from other Industrial Failures

  • What is root cause analysis (RCA)?

  • Benefits of applying RCA in mechanical component failures.

  • Different types of root cause analysis (e.g., Cause & Effect, 5 whys, fishbone diagram, etc.).

  • Introduction to standards and practices related to RCA International Standards (I.S.EN 62740-2015).

MODULE 02: Understanding Failures Profiles
  • Safety Moment – Major O&G Accidents and Key Learning Lessons. – Learn from other Industrial Failures

  • Failures Paradigm

  • P-F Curve & Swiss Chess Module

  • Failures Patterns, Distributions & Metrics Patterns & Metrics 

  • Failure mechanisms of mechanical components (e.g., Wear, fatigue, corrosion, overload).

  • Diagnosis of Engineering Failures Modes - RCA Modes

  • Factors influencing failure mechanisms (e.g., Material properties, design flaws, manufacturing defects, maintenance practices, operating conditions).

  • Failure analysis techniques (visual inspection, non-destructive testing, material testing).

MODULE 03: RCA Life Cycle " Conducting A Structured RCA Investigation"
  • Safety Moment – Major O&G Accidents and Key Learning lessons – Learn from other Industrial Failures

  • Defining the problem statement.

  • Creating a timeline of events.

  • Data gathering and information management for failure analysis.

  • Identifying potential causes using various RCA techniques (e.g., brainstorming, cause-and-effect diagrams).

  • Verifying root causes through data analysis and testing.

  • RCA Facilitator(s) & Leader(s) Responsibility & Accountability

MODULE 04: Failure Analysis of Common Mechanical Components
  • Safety Moment – Major O&G Accidents and Key Learning lessons – Learn from other Industrial Failures

  • Bearings, gears, shafts, a nd other rotating parts

  • Pumps and fan impellers

  • Hoses, belts, and couplings

  • Welded joints and pipe fittings

  • Valves, actuators, and linkages

  • Bearings and their failure mechanisms according to ISO 15243

  • Seals (lib seal, O-Ring, packing, Gasket & Flange, Mechanical seal) failure pattern analysis

  • Power transmission equipment failure modes (coupling, gear, belt)

  • Case studies of RCA investigation for pump failure patterns of pump components as a whole system (Failure Analysis Of Machine Shafts, impeller, couplings)

  • Case studies of RCA investigation of Valves, failure analysis of valve components (Failure Analysis Of Shafts, seat, disk)

MODULE 05: Diagnosis of Engineering Failures Improvement Techniques
  • Safety Moment – Major O&G Accidents and Key Learning lessons – Learn from other Industrial Failures

  • Failure mode and effect & Criticality analysis (FMECA)

  • FMECA vs. RCA.

  • Proactively identifies and addresses potential problems or failures

  • 7 Tricks to Improve Your Diagnosis of Engineering Failures (RCA)

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Jubail Industrial City, Saudi Arabia

373 road 112, First Industrial Area, Unit No.: 1 Al Jubail 35717 - 7043 KSA

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