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Course Details

PREPARE RCA FOR BASIC INCIDENT AND TAKE CORRECTIVE ACTIONS

Location
Madrid, Spain
Date
From Date: 01-Feb-2021   
To Date: 05-Feb-2021
Duration
5 Days
Language
English
Discipline
Introduction

Ref No:      REFME090
Title:          Prepare RCA For Basic Incident And Take Corrective Actions
Start Date: 01 February 2021  End Date: 05 February 2021  
Venue:       Madri, Spain
Fee:           $6,250

Training will be held at any 5 Star Hotels. Exact venue will be informed later

The natural tendency of many individuals and organisations when presented with a probl em is to jump to a solution, any solution. They do not systematically analyse the problem to determine a root cause before considering potential solutions. 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.

 

Objective

This course provides clarification of regulatory expectations and guidance,and the Essenti al skills necessary to ensure effective and efficient investigations. Topics will examine ea ch step of the investigation process from failure identification and notification through do cumentation.

Participants will practice root cause analysis techniques and Identify corrective and/or pre ventive actions towards successful remediation.

At the end of this course you should be able to:

  • Deal with the root causes of failures (Physical Roots and Human Roots.) in Industrial Activities.
  • Know How the Multiple Roots Interact.
  • Handle the General Analysis Techniques and the Root Cause Failure Analysis Methodology
  • Carry out Troubleshooting (as an Extension of Failure Analysis) and to be acquainted with the Causes of Machinery Failures. How to analyze Machinery Component Failures
  • Establishing Safe Operating Limits for Machinery and Regulatory Compliance Issues.
  • Distinguish the Sources of Stresses, Overload failures, Understanding and Recognizing Corrosion and the available effects as well as the Lubrication and co relation with Wear.
  • Understand the Interpretation of Collected Data through Vibration Analysis
  • Formalize Failure Reporting as a Teaching Tool
  • Communicate the "Seven-Cause Category Approach" to Root-Cause Failure Analysis.
Audience

This course is designed for personnel who are responsible for the failure and deviation investigation process in a GMP (global process management) environment and maintenance engineers. This course will be practical in its application and particularly valuable to those newer to this field or those who wish to refresh their knowledge of root cause analysis and investigative techniques.

Content

COURSE CONTENTS:

1. What is failure

  • THE CAUSES OF FAILURES
  • The purpose of RCFA (Root cause failure analysis)
  • EFFECTIVE USE OF THE ANALYSIS
  • PERSONNEL REQUIREMENTS
  • When to use of RCFA method

2. Understanding the roots

  • PHYSICAL ROOTS
  • HUMAN ROOTS
  • Problem- Solving Process
  • Define and Verify Root Causes
  • Corrective Actions

3. RCA Techniques

  • The Fault Tree Approach& Role of Fault Trees in a PRA
  • The 5(five) whys
  • Fault Tree Analysis
  • Fault tree construction

4. Pareto Analysis

5.Fishbone Diagram

6. HUMAN ERROR & ITS CAUSES

7. Risk management

  • QUANTITATIVE RISK (QRA)
  • QUALITATIVE RISK
  • Performance measurement

8. RCM Principles and Methodology

  • RELIABILITY AND RISK PREDICTION
  • ACHIEVING RELIABILITY AND SAFETY - INTEGRITY
  • FAILURE RATE AND MEAN TIME BETWEEN FAILURES
  • THE METHODOLOGY
  • THE RELIABILITY PREDICTION METHOD
  • The RCM task selection
  • Methods of modeling
  • The RCM implementation
  • FMEA (FAILURE MODE AND EFFECT ANALYSIS)
  • SAFETY INTEGRITY LEVELS (SIL)

9. FAILURE REPORTING

  • Collecting the Data
  • Reporting Equipment Failures
  • Reporting Software Problem

10.ANALYSIS

  • Failure Analysis Process
  • Failure Review Board
  • Root Cause Analysis
  • Failed Parts Procurement
  • Corrective action

11.Maintenance management system

  • Reactive Maintenance
  • Preventive Maintenance
  • Predictive Maintenance
  • Proactive Maintenance
  • Reliability Centered Maintenance
  • Equipment Reliability Metrics
  • Lateral learning
  • LEARNNING FROM FAILURE
  • Performance monitoring

12. Preventive / Corrective Actions (CAPA) Guidelines

  • Corrective Actions
  • Preventive Actions
  • Differences between Corrective and Preventive Actions
  • CAPA Procedures (Report Source, Explanation of the Problem, Evidence of the Problem.)
  • Evaluation (Potential Impact Assessment of Risk. Remedial Action.)
  • Investigation (Objective, Procedure, Responsibility / Resources.).
  • Analysis (Possible Causes / Data Collection, Results and Data, Root Cause Analysis)
  • Action Plan.
  • Action Implementation

NOTE: Pre & Post Tests will be conducted Case Studies, Group Exercises, Group Discussions, Last Day Review &Assessments will be carried out.

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A combination of class lectures, case studies or examples and group discussion. The course will be intensive but practical and highly interactive. Participants are encouraged to participate actively and to ask questions especially pertaining to specific problems. At the end of the session there will be a question-and-answer session to allow participants enough time to seek answers to grey areas and to seek clarifications to any misconceptions or problems they may have regarding the subject concerned to the course. There will also be some indoor experiential activities to enhance learning.

  • 30% Lectures
  • 30% Workshops and work presentation
  • 20% Group Work& Practical Exercises
  • 20% Videos& General Discussions
Fees
6,250 US$ per participant for Public Training including Course Materials/Handouts, Tea/Coffee, Refreshments & International Buffet Lunch

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