International Training Root Cause Fault Analysis

Know About Your Trainer

Our Consultant The consultant is highly respected as an global domain expert with more than 30 years in the fields of engineering and maintenance management. Prior to entering the consulting profession he held a number of technical positions with high profile international companies. He had been actively consulting Shell for a good number of years.

Our Consultant has trained in excess numbers of participants in the areas of maintenance, reliability, root cause analysis, production, materials, productivity, and logistics. Training presented in various African , Middle Eastern countries. He has experience in consulting for the private sector, government and educational institutions. He has trained and consulted for companies such as Shell Nigeria, Suffolk Petroleum, Mondi Paper, De Beers Group, as well as ESKOM in South Africa.

Our consultants line of position and responsibility includes development engineer with the focus on rotating equipment, particularly turbo-machinery with rotor-dynamics as main interest for projects expedited. After that he migrated to vibration analysis (reflection on rotor-dynamic behaviour), condition monitoring and eventually equipment reliability and developing/ testing high speed rotating equipment for Vibrakon as a Founder, consultant and director.

Our Consultant is currently focusing as a lead consultant on the implementation of equipment reliability programs with the original design/development/investigative background contributing to a thorough understanding of the design environment’s influence on equipment reliability for various clients internationally. CSIR Defence Research Institute

Course Description

Root Cause Fault Analysis training provides the concepts needed to effectively perform industrial troubleshooting investigations. RCFA Training covers the methodology to perform Root Cause Failure Analysis, Failure Modes and Effects Analysis (FMEA), Fault Tree Analysis (FTA), and other hot topics currently in maintenance engineering.

RCFA Training also includes detailed design and troubleshooting guidelines, investigating techniques for system failures, which are needed to perform problems found in most production facilities. Root cause failure analysis helps you to identify what, how and why something happened, thus preventing recurrence. Root causes can be controlled by management and allow for generation of recommendations. Root Cause Failure Analysis is a powerful tool you can uses to focus on the source of the equipment failure to prevent future failures.

By End Of This Course

• Identify common manufacturing errors and deviations

• Identify the origin of a problem, determine what happened, why it happened and figure out what to do to reduce the likelihood that it will happen again

• Compare common root cause analysis tools and methods such as events and casual factor charting, change analysis, barrier analysis, tree diagrams, why-why chart, Petro analysis, storytelling method, fault tree analysis, failure modes and effect analysis, reality charting and other methods

• Use Failure Modes and Effects Analysis (FMEA) techniques (DFMEA and PFMEA)

• Learn when and how to use Fault tree analysis(FTA) as a top down, deductive failure analysis

• Learn when to use cause and effect Fishbone (Ishikawa) diagram

• Develop and implement effective and efficient root cause failure analysis programs

• Assess how to make RCFA a structured, team based, analytical approach

WHO SHOULD ATTEND

Managing Directors, CEOs, Vice Presidents, General Managers, Directors, Heads, Managers Administration and Team Leaders
• Maintenance
• Reliability
• Plant
• Engineering
• Technical Management
• Operations & Production
• Integrity Management
• Project Engineers
• LEAN Specialists
• 6 Sigma Black Belts
• Reliability Engineer
• Maintenance – Stationary Engineer
• Health, Safety & Environment Officer
• Operations Engineer
• Maintenance – Machinery
• Graduate Trainee’s
• Business Analysts

Course Outline

  • DAY ONE


  • Understanding what Impacts the Organisation

  • · Costs of unreliability
    · Equipment failure
    · Processes
    · People
    · Procedures and training
    · ISO 55000 directed RCFA based Improvements

  • Introduction to RCFA

  • · Introduction to RCFA
    · RCFA Terminology
    · RCFA Techniques (5 Why/Fishbone/Fault trees/Cause Mapping)

  • Cause Mapping as the Basis to Risk Mitigation and Reliability Improvement

  • · 5-Why as Basis to Cause Mapping
    · Expanding the investigation
    · Blame vs. Prevention
    · RCFA vs. FMEA
    · Risk mitigation

  • Workshop-1

  • · Reliability audit
    · Applying the different RCFA techniques
  • DAY TWO


  • Important RCFA Elements:

  • · RCFA incident and equipment failure recording (FRACAS)
    · RCFA, risk and reliability relationship
    · RCFA scale
    · RCFA teams
    · RCFA facilitation
    · RCFA reporting

  • Typical Steps in RCFA (Reactive)

  • · Record (timeline) the event
    · Protect the evidence/perform creative disassembly
    · Define the problem/severity of the event (impact on company goals)
    · Establish scale of RCFA and assign appropriate RCFA team
    · Analyse the data
    · Identify possible solutions and assign responsibilities
    · Report on the RCFA investigation
    · Implement solutions
    · Evaluate the benefits of the solutions

  • Introducing RCFA to the organisation

  • · The Change Management process
    · Getting buy-in from the right people

  • Failure Prevention Measures (Proactive):

  • · Focussed Maintenance (Hierarchy, Criticality, Workflow, RCM, PMO)
    · Other Reliability Essentials (Procedures, Precision & Proactive Maintenance and ODR)
    Workshop-2
    Applying Cause-Mapping on examples from attendees

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