Root Cause Failure Analysis
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Program Professional Framework
Root Cause Failure Analysis
Program Overview
Repeated failures of pumps, bearings, seals and electrical equipment consume maintenance budgets and production time when only the symptoms are fixed. This course teaches a disciplined approach to finding and eliminating the physical, human and latent causes of equipment failures. Participants learn to preserve evidence, read failure surfaces and recognize mechanisms such as fatigue, overload, wear and corrosion, and apply tools including 5 Whys, cause-and-effect diagrams, fault trees and logic trees. The course also covers prioritizing which failures to investigate, writing effective recommendations and tracking them to closure.
Learning Outcomes
- ✓Select failures for investigation using criteria such as repeat frequency, cost and safety impact.
- ✓Collect and preserve failure evidence including parts, data, photographs and witness accounts.
- ✓Identify common mechanical failure mechanisms from the appearance of failed components.
- ✓Build a logic tree or fault tree that distinguishes physical, human and latent causes.
- ✓Write corrective actions that address latent causes and assign owners and deadlines.
- ✓Verify the effectiveness of corrective actions using failure recurrence and reliability data.
Target Audience
- Reliability and maintenance engineers
- Maintenance supervisors and planners
- Operations engineers and process engineers
- Inspection and integrity engineers
Detailed Program Modules
01Principles of Failure Analysis
- Symptoms, failure modes and root causes
- Physical, human and latent causes
- Building an RCFA program
02Selecting and Preparing Investigations
- Criteria for triggering an RCFA
- Forming the investigation team
- Evidence preservation and data collection
03Failure Mechanisms
- Fatigue, overload and brittle fracture
- Wear, erosion and corrosion
- Reading fracture surfaces
04Analysis Tools
- 5 Whys and cause-and-effect diagrams
- Fault tree and logic tree analysis
- Timeline and change analysis
05Common Equipment Failures
- Bearing and mechanical seal failures
- Pump and shaft failures
- Electrical motor failures
06Corrective Actions and Follow-Up
- Writing effective recommendations
- Action tracking and closure
- Measuring improvement in reliability
Training Methodology
Applied Project & Assessment
Applied Project
Participants conduct an RCFA on a recurring failure from their plant or a provided case, presenting the evidence, logic tree, identified root causes, corrective actions and a plan to verify their effectiveness.
Assessment
Short diagnostic at the start, practical tasks linked to each learning outcome, and evaluation of the applied project against published criteria.