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Engineering
Quality Management

Root Cause Failure Analysis (RCFA)

Session Details

Khobar

USD 4,200

excl. VAT
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Overview

Failure analysis has historically been viewed as the domain of technical specialists, using complicated tools and programs to inform maintenance and operating teams what they have done incorrectly. This course demystifies failure analysis and places it in the hands of the maintenance and operating organizations in order to enable greater asset reliability. The course explores models such as Root Cause Failure Analysis (RCFA) and Failure Modes and Effects Analysis (FMEA); it demonstrates how these can be broken down into simple steps that can engage the whole organization, from the operating team to the technical specialists. The course also covers effective failure control and how to learn from the failure investigation or failure prevention analysis to not just identify the problem, but to implement effective robust controls as well in order to prevent future similar failures across an organization’s assets. As well as best-in-class visuals and slides, this course includes a high level of interaction between the facilitator and participants to ensure the course is meeting their specific requirements. Numerous relevant case studies are utilized to demonstrate key points and a series of exercises are conducted to apply learning and to appreciate key aspects of best practice.

Learning Objectives

By the end of the course, participants will be able to: Understand equipment function and therefore skillfully identify equipment failure Effectively investigate equipment failure incidents to understand root causes Implement effective controls to avoid similar incidents occurring Engage their organization to achieve more effective failure investigation Analyze critical equipment systems to avoid future failure

WHO SHOULD ATTEND?

The Root Cause Failure Analysis course is ideal for professionals involved in troubleshooting, problem-solving, and improving operational reliability and performance. Typical participants include: Maintenance and Reliability Engineers Operations and Production Managers Quality Assurance/Quality Control Personnel Health, Safety, and Environment (HSE) Professionals Engineering and Technical Staff Process Improvement Specialists (Lean, Six Sigma) Supervisors and Team Leaders Project and Asset Managers Failure Analysts and Investigators Anyone responsible for identifying and resolving recurring problems, reducing downtime, or improving equipment and process performance will benefit from this training. No prior experience in RCFA is required, but a basic understanding of engineering or operational processes is helpful

COURSE METHADOLOGY

BK ManagementTeam believe 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 an individual and as a team player. The course delivery & modes of instruction will incorporate theory , practical skills and Q&A sessions. To enhance learning outcomes, theory sessions will comprise classroom based lecture that will intersperse with interactive discussions, scenario-based, case-study, group exercises, video clips, power point slides, learners' Guide and the application of various tools which will be provided to help in the delegates and participants of the learning’s objectives. With successful implementation of the learnt skills they are bound to enhance Individual & Organizational growth. For online / Interactive Virtual sessions, Delegate should have a stable & good Internet connection on his laptop.

Course Outline

MODULE 1:

Incident Identification RCA Concept

• Organization RCA workflow, and Roles & Responsibilities

• Incident Preparation

  1. Team Scope, Selection, Leader & Member Roles & Responsibilities

  1. Site Visit

  2. Investigation Success Factors & Work plan

• Data Gathering

  1. Identifying Required Data

  2. Data Sources & Collection

  3. Interview Technique

  4. Data Synchronizing

How Incident Happened?? (Timeline Tool & Construction)

MODULE 2:

• 5 Whys Methodology + Exercise (Single Investigation for small incidents)

• Human Error Analysis (Identifying & Analyzing Human Error

MODULE 3:

Fishbone Methodology + Exercise (Team Investigation IMODULE 4: Fault Tree (Cause & Effect) Methodology + Exercise (Team Investigation Methodology) IMODULE 5: Cont. Fault Tree (Cause & Effect) Methodology + Exercise (Team Investigation Methodology) Methodology)

MODULE 4:

Fault Tree (Cause & Effect) Methodology + Exercise (Team Investigation Methodology)

MODULE 5:

Cont. Fault Tree (Cause & Effect) Methodology + Exercise (Team Investigation Methodology)

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