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Course Description

Problems do happen in our facilities. Merely uncovering factual root causes does not solve or reduce the risk or failure. Unless recommendations, corrective and proactive actions are appropriate, approved and implemented, the problems will continue to exist. Management expects to receive solid, factual data and information in the analysis to support and approve funds for implementing recommendations. ​RCA practice tries to solve problems by attempting to identify and correct the root causes of events, as opposed to simply addressing their symptoms. By focusing correction on root causes, problem recurrence can be prevented. RCFA (Root Cause Failure Analysis) recognizes that complete prevention of recurrence by one corrective action is not always possible. Root cause analysis is not a single, sharply defined methodology; there are many different tools, processes, and philosophies for performing RCA. 

In our course we will present clear understanding of different RCA tools, sequences and undergo exercises that will pave the road for immediate application for the RCA concepts into your everyday operations.

Course Objectives

Upon the successful completion of this course, each participant will be able to:​

  • Understand the basics of RCA and its relation to modern management and maintenance
  • Understand the difference between failure modes, failures and failure effects
  • Understand the difference sporadic, chronic and cascading failures
  • Present in theory and practice through exercises the different RCA tools
  • Relate RCA analysis and tools to other maintenance methodologies and Management
  • Present Actual case studies of complex situations 

Who Should Attend?

This course is designed for engineers, operators, technicians, supervisors, designer and process engineers.

Course Agenda

Welcome & Introduction

Pre-Test

  • Logic vs Intuition
  • What is a Problem?
  • RCA applications
  • Generations of Maintenance and relation to RCA

Concept of Failure

  • Machine Failure
  • Types of Failure Causes
  • Effect of Failure
  • Failure Cascading
  • Failure Modes
  • Chronic vs. Sporadic Problems

Root Cause Failure Analysis process

  • What RCFA is?
  • Why it is done?
  • Types of Root Causes
  • 7 Generic Steps in an RCFA
  • Challenges in Setting up RCFA

Failure Modes & Effects Analysis

  • Failure Analysis Methods
  • Implementing FMEA
  • FMEA Procedure
  • FEMA exercises

Understanding and Investigation

  • The Ishikawa Diagram
  • Fault Tree Analysis
  • Pareto Charts
  • Sequence of events
  • 5 Whys technique
  •    Human Factor in RCA: The decision cycle and blame culture

A closer look at Maintenance types

  • Prerequisites for Break-down and Corrective Maintenance
  • Preventive Maintenance
  • Condition Monitoring as the maintenance breakthrough
  • Proactive Maintenance

Case studies and SW tools

  • Dust Explosions RCA
  • Assignment case studies discussion
  • Cause Map using EXCEL

Post Test / End of Course

Assessment Methodology

All courses conducted by EdTech are begun with a written Pre-evaluation and end with a Post-evaluation. The instructor will evaluate the knowledge and skills of the participants according to the feedback given by participants. This proactive method will help to recognize the benefits and knowledge gained by participants through the course.

Training Methodology

Facilitated by a highly experienced specialist; this program will be conducted using extensively interactive methods, encouraging participants to share their own experiences and apply the program material to real-life work situations in order to stimulate group discussions and improve the efficiency of the subject coverage. Percentages of the total course hour classification are:

  • 30% Theoretical lectures, Concepts and Role Play
  • 30% Work Presentation and Techniques
  • 20% Case Studies and Practical Exercises
  • 20% Topic General Discussions with Relevant Videos.

Course Manual

Participants will be provided with a comprehensive reference manual. This manual is a compilation of core valuable information, references, presentation methods and inspiring reading materials.

Course Certificate

At the completion of the course, all participants who successfully accomplished the required contact hours will receive an EdTech Course Completion Certificate as a testimony to their commitment to professional development and further education.

Why Edtech ?

  • Industry Experienced; Internationally Qualified Trainers
  • Hands-on Practical Sessions & Assignments
  • Intensive Study materials
  • Flexible Schedules
  • Realistic training methodology
  • High-Quality Training in Affordable Course Fees
  • Achievement Certificate, as approved by the Ministry of Education (Abu Dhabi Center for Technical and Vocational Education Training - ACTVET), HABC, AWS, IAOSHE, SHRM, etc.