Objective:

Reliability engineering and predictive maintenance have two major objectives: preventing catastrophic failures of critical plant production systems and avoiding deviations from acceptable performance levels that result in personal injury, environmental impact, capacity loss, or poor product quality. Unfortunately, these events will occur no matter how effective the reliability program. Therefore, a viable program also must include a process for fully understanding and correcting the root causes that lead to events having an impact on plant performance.

This course provides a logical approach to problem resolution. The method can be used to accurately define deviations from acceptable performance levels, isolate the root causes of equipment failures, and develop cost-effective corrective actions that prevent recurrence.

Root Cause Analysis provides the concepts needed to effectively perform industrial troubleshooting investigations. It describes the methodology to perform root cause analysis (RCA), one of the hottest topics currently in maintenance engineering. It also includes detailed equipment design and troubleshooting guidelines, which are needed to perform RCA on machinery found in most production facilities.

This course is designed to provide the delegate with a thorough overview of the Root Cause Analysis (RCA) process coupled with a sound knowledge of the underlying principles. The fundamental principles are established and then built upon using a combination of advanced presentation techniques, informal delegate instructor interaction and formal scripted syndicate and individual exercises. The course begins by defining RCA and then considers generic plant equipment troubleshooting examples.

The subsequent modules cover the analytical tools used by the RCA Analyst and address the requirements of each stage of the RCA methodology.  A short conclusion session rounds off the day and allows the delegates to consolidate their knowledge and allows points of clarification to be addressed.

 

Course Agenda:

Introduction to Root Cause Failure Analysis

                RCA; Address the cause, not just the symptom

            Root Cause Investigation Concept

            Root Cause; Definition

                Root Cause Analysis; Basics

            Accidents and Failures; the iceberg model

            Symptom approach Vs. Root Cause

            Root Cause Investigation Process

            RCA Applications

RCFA in the Maintenance Management System

                Maintenance and Maintenance Management

            Maintenance Revolutions and Policies

            RCFA; a proactive maintenance strategy

Machinery Failure Prevention

Zero-Failure performance

Proximate causes and Root Causes

Machinery and equipment Failure causes

Root Cause Failure Analysis; The concept

        Root Cause Analysis Defined

          The Root System; Physical, Human, and Latent root Causes

        Root Cause identification

          The Loss Causation Model

        RCA; Objective, purpose, and effectiveness.

          Personal requirement

          When to use?

          Process of RCA           

How to make RCFA a successful business improvement strategy?

 

Root Cause Analysis Techniques

          5 why process

Cause Mapping

Cause and Effect Analysis (Fishbone Analysis)

Fault Tree Analysis

Sequence of event analysis    

 

Root Cause Failure Analysis methodology

Reporting an Incident or Problem.

            Systems and boundaries

            Perceived cause of problem

            Event-reporting format

Incident Classification.

Data Gathering.

            Interviews

            Questions to ask

            Type of interviews

            Collecting physical evidence

            Analyze sequence of Events

Design Review.

            Minimum design data

Acceptable Operating Envelope

Application / Maintenance Review.

            Installation

             Standard Operating Procedures (SOPs) and Practices

            Maintenance history

            Maintenance procedures and practices

Observations and Measurements.

Determining the Root Cause.

Evaluating Potential Corrective actions

Cost – Benefit Analysis.

Report and Recommendations.

Verify Corrective Action.

 

 

To register, call 01067385500 or 01064749611 or send an email to; training@resglobal.org

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