🎯 Course Description:
This comprehensive 5-day course equips participants with systematic methods and tools for identifying the root causes of equipment and process failures in industrial facilities.
Through practical exercises, case studies, and proven methodologies like the 5 Whys, Fishbone Diagram (Ishikawa), Fault Tree Analysis (FTA), and Failure Mode and Effects Analysis (FMEA), participants will learn to prevent recurrence, improve reliability, and reduce downtime.
👥 Who Should Attend:
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Maintenance and Reliability Engineers
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Quality and Process Improvement Professionals
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Failure Analysis and Root Cause Investigation Teams
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Operations and Production Supervisors
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Asset Management Professionals
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Continuous Improvement and Safety Personnel
🗓️ Day 1: Introduction to Root Cause Failure Analysis
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Fundamentals of RCFA – Importance, benefits, and scope |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Failure Types and Modes – Common causes and classifications |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | RCFA Process Flow – Steps from failure identification to corrective action |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Case Study: Analyze a real failure and initial data gathering |
🗓️ Day 2: Data Collection and Problem Definition
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Effective Data Gathering – Techniques, interviews, documentation |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Problem Statement & Scope Definition – Clear articulation of failure |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Using Evidence – Photographs, measurements, operational logs |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Develop a failure problem statement from sample data |
🗓️ Day 3: Root Cause Analysis Tools and Techniques
| Time | Topic |
|---|---|
| 08:30 – 10:00 | The 5 Whys Technique – Iterative questioning to drill down root causes |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Fishbone Diagram (Ishikawa) – Categorizing causes into Man, Machine, Method, Material |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Fault Tree Analysis (FTA) – Logical graphical representation of failure pathways |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Construct a Fishbone diagram and apply 5 Whys on case examples |
🗓️ Day 4: Advanced RCFA Techniques and Failure Modes
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Failure Mode and Effects Analysis (FMEA) – Proactive identification of risks |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Reliability Centered Maintenance (RCM) Basics – Link with RCFA |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Data Analysis Tools – Trend analysis, Pareto charts, and statistical tools |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: FMEA case study and risk prioritization exercise |
🗓️ Day 5: Implementing Corrective Actions and Reporting
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Developing Effective Corrective Actions – SMART actions, implementation planning |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Verification and Follow-up – Ensuring actions resolve the root cause |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Report Writing and Communication – Documenting findings, communicating with stakeholders |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Group Exercise: Complete an RCFA report on a provided failure scenario |
📂 Course Materials Provided:
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RCFA process and methodology handbook
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Templates for data collection, problem statements, and reports
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Sample Fishbone, FTA, and FMEA worksheets
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Case studies and real-world failure scenarios
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Corrective action planning checklists
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Presentation slides and facilitator notes
