🎯 Course Description:
This comprehensive course provides participants with the knowledge and tools to systematically identify, analyze, and prevent root causes of failures in mechanical, electrical, and process equipment across various industries. The training covers failure modes, root cause analysis techniques, investigation methods, and corrective actions to improve equipment reliability and reduce downtime.
Participants will engage in practical case studies, data analysis exercises, and workshops to develop strong analytical and problem-solving skills.
👥 Who Should Attend:
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Maintenance engineers and technicians
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Quality assurance and control personnel
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Reliability and integrity engineers
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Root cause analysts and investigators
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Plant managers and supervisors
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Anyone involved in failure investigation and prevention
🗓️ Day 1: Introduction to Failure Analysis
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Objectives, Participant Introductions |
| 09:00 – 10:30 | Overview of Failure Types and Mechanisms |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Common Causes of Failures – Corrosion, fatigue, wear, overload |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Failure Modes and Effects Analysis (FMEA) |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Identifying failure modes from real equipment data |
🗓️ Day 2: Root Cause Analysis Tools and Techniques
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Root Cause Analysis (RCA) Fundamentals |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Common RCA Techniques – 5 Whys, Fishbone Diagram, Fault Tree |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Data Collection and Evidence Gathering |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Group Exercise: Conducting RCA on sample failure scenarios |
🗓️ Day 3: Failure Investigation Process
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Failure Investigation Planning and Execution |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Material Analysis and Laboratory Testing |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Inspection and NDT Methods in Failure Analysis |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Case Study: Comprehensive failure investigation walkthrough |
🗓️ Day 4: Corrective Actions and Prevention Strategies
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Developing Corrective and Preventive Actions |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Risk Assessment and Management to Avoid Recurrence |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Reliability-Centered Maintenance (RCM) and Failure Prevention |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Creating action plans based on RCA findings |
🗓️ Day 5: Reporting, Documentation, and Continuous Improvement
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Effective Failure Reporting and Documentation |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Lessons Learned and Continuous Improvement Processes |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Mock RCA Session and Group Presentations |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Materials Provided:
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Failure Analysis and Root Cause Investigation Handbook
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RCA Tools Templates (5 Whys, Fishbone diagrams)
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Case Studies and Workshop Exercises
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Failure Reporting and Documentation Formats
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Continuous Improvement Checklists
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Certificate of Completion
