COURSE INTRODUCTION
This programme provides a structured approach to investigating equipment failures and preventing recurrence. Participants learn to preserve evidence, define what failed, analyse contributing causes, distinguish failure types, identify root causes and develop corrective actions that move maintenance teams beyond repeated reactive repair. Practical examples and guided discussion help participants connect the subject to decisions and challenges in their own workplace.
COURSE OBJECTIVES
By the end of this programme, participants should be able to:
- Explain the core concepts, terminology and working principles related to Root Cause Failure Analysis.
- Apply structured methods and industry good practices for Introduction to Root Cause Analysis (RCA), Preparation Root Cause Analysis, and Establish What Failed.
- Evaluate relevant quality & root cause situations and identify risks, gaps and improvement opportunities.
- Translate the learning into practical workplace actions and sound technical decisions.
COURSE OUTCOME
Upon completion, participants will be better prepared to:
- Assess relevant workplace situations using the concepts and methods covered in Root Cause Failure Analysis.
- Select and apply appropriate tools, checks or controls for Introduction to Root Cause Analysis (RCA), Preparation Root Cause Analysis, and Establish What Failed.
- Recommend actions that support structured investigation, evidence-based decisions and recurrence prevention.
- Communicate findings, improvement opportunities and next steps clearly to relevant stakeholders.
WHO SHOULD ATTEND
Maintenance - Techs, Supervisors, Engineers, PM Techs, Equipment Personals.
COURSE CONTENT
- Module 1: Introduction to Root Cause Analysis (RCA): What is root cause analysis; Why analyze root cause; Current fix and run attitude
- Module 2: Preparation Root Cause Analysis: three major weakness in Root Cause Analysis; Step # 1 : found out what happened; Step # 2 : make preliminary investigation
- Module 3: Establish What Failed: Analyzing the initial evidence; Identifying the four components of a failure; What is the effect
- Module 4: Analyze the Causes of a Failure: Current analysis short fall; Lack of techniques; Step # 5 : Analyze the Root Cause of Failures
- Module 5: Establish the failure causes: step 6. determine the failure type; human non-adherence; procedural violations
- Module 5: Establish the Failure Causes: Step # 6 : Determine the Failure Type; Machine malfunction
- Module 6: Determine the Root Cause: Step # 7 : Establish the root cause; Current pitfalls in determining root cause; Key requirements before determining the root cause
- Module 7: Eliminating Reoccurrence: Step # 8 : Develop permanent corrective actions; Short term immediate countermeasure; Long term permanent solution through PDCA
- Module 8: Moving Away from RCA: Step # 9 : Embark on proactive maintenance; RCA should not be a long-term activity; Strategy for proactive maintenance
- Root Cause Analysis "kaizen" cycle
