Course Description:  

Root Cause Failure Analysis (RCFA), as one of the hottest topics currently in maintenance engineering, provides the concepts needed to effectively perform industrial troubleshooting investigations. This 5-day course describes the methodology to perform RCFA. It also includes detailed equipment design and troubleshooting guidelines, which are needed to perform RCFA on machinery found in most production facilities.

Course Goal:

To enhance the participant’s knowledge, skills, and abilities necessary to understand and apply the RCFA in way based on the good acquaintance with the modern technologies applied in this field

Course Objectives:

By the end of the course, participant will be able to:

1. Identify common manufacturing errors and deviations
2. Understand how to prioritize failure events to analyze, preserve failure data, and order a failure analysis
3. Explore systems failure analysis methods and techniques
4. Develop and implement effective and efficient root cause failure analysis programs
5. How to make RCFA a structured, team based, analytical approach

Course Outline:

• Introduction to Root Cause Failure Analysis.

1. Purpose of the analysis.
2. Effective use of the analysis.
3. Personnel requirements.
4. When to use the method.
5. The NINE Steps in RCFA Process:

• Define Problem/Collect Data
• Task Analysis
• Change Analysis
• Control Barrier Analysis
• Event and Causal Factor Charting
• Interviews
• Determine Root Cause
• Develop Corrective Actions
• Report
• General Analysis TECHNIQES.

1. Failure mode and effective analysis.
2. Fault-tree analysis.
3. Cause-and-effect analysis.
4. Sequence-of-events analysis.
5. Reporting an incident or problem.
6. Symptoms and boundaries.
7. Perceived cause of problem.
8. Event –reporting format.
9. Incident classification.
10. Data gathering.
11. Collecting physical evidence.
12. Design review.
13. Application/Maintenance review.

• Equipment Troubleshooting Guide.

1. Pumps.
2. Fans, Blowers and Fluidizers.
3. Conveyors.
4. Compressors.
5. Mixers and Agitators.
6. Gearboxes or Reducers.
7. Control Valves.

• Seals and Backing