Root Cause Analysis: Uncover Hidden Problems

Course overview

What is the root cause analysis?

There are numerous reasons why machines and equipment, both static and moving, fail. Some reasons why things go wrong seem obvious or straightforward, yet they can just be covert reasons. In terms of construction material, corrosion, stress processes, the spread of microstructure intergranular cracks, etc., or other related aspects surrounding machines and equipment, such as operation, inspection, maintenance, methods, human machine interface, and the overall management around these, among other factors, may be the actual root causes.

Regardless of the reasons for failure, accidents with Health, Safety and Environmental (HSE) consequences as a result of these devices and equipment failing in the oil and gas industries are becoming more commonplace worldwide. These incidents cause serious human injuries as well as fatalities due to significant follow-on incidents like fire, explosion, toxic/lethal discharges, etc. According to the stakes and risks involved, the relevant industry must pay close attention to the causes of these machine and equipment failures and take all reasonable steps to prevent, minimize, and contain these failures; otherwise, a company’s assets could be completely destroyed by a rapid escalation of incidents beyond its control.

Why do a ‘Root Cause Failure Analysis’?

Root Cause Failure Analysis gives an organization a systematic methodology and activities to minimize/eliminate the failures that ultimately hurt people, damage equipment or property, result in lost output, or have a detrimental impact on the environment. By the end of the training session, you will be able to produce a root cause failure analysis report with the help of our team of professionals.

Introduction

The Root Cause Failure Analysis (RCFA) certification course is a specialist training program created to give people the information, abilities, and methodologies required to find and fix the underlying causes of failures in a variety of situations. This thorough course is designed for people working in fields including manufacturing, engineering, healthcare, aviation, and other fields where failure analysis is crucial.

Engineers, maintenance workers, quality assurance specialists, safety officials, and managers are just a few of the people whose backgrounds would make the RCFA certification course appropriate for them. It is especially useful for individuals in charge of making sure that systems, tools, and procedures are reliable and safe.

We are The Training Bee, a global training and education firm providing services in many countries. We are specialized in capacity building and talent development solutions for individuals and organizations, with our highly customized programs and training sessions.

Participants are anticipated to have developed a solid foundation in failure analysis principles, practical abilities in identifying root causes, and the capacity to create preventive measures after finishing the RCFA certification course. By successfully resolving problems at their underlying causes, they should be well-equipped to contribute to organizational resilience, increase operational efficiency, and improve safety.

Learning Objectives

Upon completing Root Cause Failure Analysis (RCFA), participants will be able to:

• Learn the basic ideas behind moving and stationary equipment and machine breakdowns.
• Recognize the connection between equipment and machine failures and the related HSE issues.
• Understand the main major machines and equipment’s identified failure modes.
• Discover the root and common causes of equipment and machine failures by using Root Cause Failure Analyses (RCA).
• Examine the success of the CAP and PAP implementation.
• Acquire knowledge about and practice in producing RCFA reports.
• Recognize the significance of RCFA Close-out

Our Unique Training Methodology

This interactive course comprises the following training methods:

• Journaling – This consists of setting a timer and letting your thoughts flow, unedited and unscripted recording events, ideas, and thoughts over a while, related to the topic.
• Social learning – Information and expertise exchanged amongst peers via computer-based technologies and interactive conversations including Blogging, instant messaging, and forums for debate in groups.
• Project-based learning
• Mind mapping and brainstorming – A session will be carried out between participants to uncover unique ideas, thoughts, and opinions having a quality discussion.
• Interactive sessions – The course will use informative lectures to introduce key concepts and theories related to the topic.
• Presentations – Participants will be presented with multimedia tools such as videos and graphics to enhance learning. These will be delivered engagingly and interactively.

Training Medium

This Root Cause Failure Analysis (RCFA) training is designed in a way that it can be delivered face-to-face and virtually.

Course Duration

This training is versatile in its delivery. The training can be delivered as a full-fledged 40-hour training program or a 15- hours crash course covering 5 hours of content each day over 3 days

Pre-course Assessment

Before you enroll in this course all we wanted to know is your exact mindset and your way of thinking.
For that, we have designed this questionnaire attached below.

• What does the term “Root Cause Failure Analysis” (RCFA) mean?
• What do you think the main goals of RCFA in a company should be?
• Have you ever taken part in any RCFA projects or activities? In that case, kindly share your experience.
• What led you to sign up for this certification course if you have no prior RCFA experience?
• Could you name a few typical reasons you are aware of for equipment or process failures?
• Do you have any particular failure occurrences that you would like to learn more about during this course?
• Are there any RCFA approaches or tools that you are acquainted with, such as the “5 Whys” or “Fishbone” (Ishikawa) diagrams?

Course Modules

This Root Cause Failure Analysis (RCFA) covers the following topics for understanding the essentials of the Agile Workplace:

Module 1 – Basic Ideas and a Few Failure Analysis Tools

• Predictive maintenance and reliability engineering
• Analysis of Failure Mode and Effects
• Vulnerability Analysis
• Cause-and-Effect Investigation
• The Bow-Tie approach of the Fishbone Graph Sequence-of-Events diagram

Module 2 – Methodology of Root Cause Failure Analysis

• Reporting an incident of failure or a problem.
• Boundaries/Conditions and Symptoms.
• Issues perceived causes.
• Format for Event Reporting.
• Types of Failure Incidents.
• An example of a failure incident report form.
• Equipment failure or damage

Module 3 – Identifying the Failure’s Primary Cause(s)

• Poor design techniques
• Depreciation, remaining life, and replacement planning are not predictive as people age.
• Purchasing Procedures: Low bid against lifecycle cost, inadequate specifications, substitutions, vendor evaluations,
• Shoddy operation, inspection, and upkeep Procedures and Practices
• Lackluster Education Inadequate Supervision
• Effortless Communication

Module 4 – Considering Possible Corrective Actions

• SME (Subject Matter Experts) participation
• Risk Assessment Matrix for HSE.
• Regulatory Conditions
• Process, materials, labor, training, and other costs are involved.
• Benefit-Cost Analysis
• A managerial choice

Module 5 – Recommendations and Report

• Summary of a Failure Incident
• Description of the Initial Plant Condition Initiating Event Failure Incident
• Quick corrective measures
• Long-Term Corrective Actions and the Causes
• Reports, both internal and external Lessons Learned filed

Module 6 – Issues Relating to HSE

• Physical Deficit
• Personal Issues
• Repetition/boredom Unfriendly machine-human interface
• Operations Issues, workarounds, and capacity expansion
• Economic factors to disregard HSE best practices

Module 7 – Issues with Internal and Regulatory Compliance

• Legislation governing worker responsibilities, reporting requirements, and the Pollution Control Board, if failures result in it.
• Process Safety Management (PSM) | Occupational Health & Safety Management | ISO 45001:2018
• Resource Conservation and Recovery Act Emergency Planning and Community Right-to-Know Act

Module 8 – Considerations for Design Evaluation: Selected Machines & Equipment

• Blowers, fans, and fluidizers
• Conveyor belts and conveyors in motion
• Agitators and Mixers
• Collection of dust
• Rollers
• Fasteners
• Cables and ropes
• Transmissions/Speed Reducers

Module 9 – Case studies, live failure incidents, and RCFA exercise

• Failure conversations and videos
• To refresh the audience, the tutor applies the RCFA methodology to a case study of a single incidence.
• Other case studies are presented by the tutor, who instructs the students to use RCA and investigation reports to solve them.
• Tutor tracks development and offers assistance
• Query and response

Post-course Assessment

Participants need to complete an assessment post-course completion so our mentors will get to know their understanding of the course. A mentor will also have interrogative conversations with participants and provide valuable feedback.

• Give a brief definition of Root Cause Failure Analysis (RCFA).
• Describe the main goals and advantages of using RCFA in an organizational setting.
• Describe at least two distinct RCFA techniques or instruments that were discussed in the course.
• Give an example of a situation where you would utilize each of these techniques in the real world.
• Describe the role that data gathering and analysis play in the RCFA process.
• Which ways for gathering data and analyzing it did you found to be most helpful during the course?
• List the essential components of an RCFA report or other paperwork.
• What details ought to be present in an RCFA report to guarantee its usefulness and clarity?

Lessons Learned

Participants gain knowledge about the value of a structured and methodical approach to problem-solving. By offering a framework to identify the root causes of failures, the RCFA enables businesses to address problems at their root.

The RCFA places a strong emphasis on the advantages of proactive measures versus reactive ones. Participants are aware that they can avoid repeating failures, cut downtime, and save money by locating and treating underlying causes.

Data-Driven Decision-Making: To identify root causes, RCFA uses data collecting and analysis. Participants are aware of the importance of statistics for making wise decisions and guiding efforts towards continual improvement.

Participants discover that effective RCFA frequently necessitates cooperation across cross-functional teams. A more thorough grasp of difficult topics is made possible by many viewpoints and areas of expertise.