Course Details

Objective

Provide the knowledge and skills necessary to facilitate and understand how to maximize the result of your RCA program.

Applying ROOT CAUSE ANALYSIS to solve all types of problems. you can  investigate errors, defects, failures, losses, outages and incidents in a wide variety of industries

The course is designed to enable the candidate to work out an investigation and document  the root cause of all the problems relating to equipment and human error and equipment failure that results in loss of productivity, accident and damage.

Topics covered

• Problem Definition.
• The cause & effect principle.
• Cause & effect charting
• Cause & effect charting (cont’d)
• Identifying solutions.
• Reality charting software.
• Gathering data
• Putting it all together

Content

Day1

1 Failure of Machines and Inspection Based Failure Analysis

Failure analysis tools

Failure Mode & Effects Analysis

Root Cause Analysis

2 Causes of Machinery Failure –

Industrial failure

Introduction

Wear mechanisms, fatigue, fretting, and corrosion and electrolytic.

Equipment, failure and maintenance data

Causes and implication

Hazards

Thermal and chemical stability data and hazardous effects of inadvertent mixing of different material

Day 2

General principles of root cause analysis

General process for performing and documenting an RCA-based Corrective Action

1. Define the problem.
2. Gather data/evidence.
3. Ask why and identify the true root cause associated with the defined problem.
4. Identify corrective action(s) that will prevent recurrence of the problem (your 100 year fix).
5. Identify effective solutions that prevent recurrence, are within your control, meet your goals and objectives and do not cause other problems.
6. Implement the recommendations.
7. Observe the recommended solutions to ensure effectiveness.
8. Variability Reduction methodology for problem solving and problem avoidance.

Day 3

Root cause analysis techniques

• desired.
• Failure mode and effects analysis
• Fault tree analysis
• 5 Whys
• Ishikawa diagram, also known as the fishbone diagram or cause-and-effect diagram. Pareto analysis
• RPR Problem Diagnosis -

Day 4

Basic elements of root cause

• Materials
  • Defective raw material
  • Wrong type for job
  • Lack of raw material
• Machine / Equipment
  • Incorrect tool selection
  • Poor maintenance or design
  • Poor equipment or tool placement
  • Defective equipment or tool
• Environment
  • Orderly workplace
  • Job design or layout of work
  • Surfaces poorly maintained
  • Physical demands of the task
  • Forces of nature
• Management
  • No or poor management involvement
  • Inattention to task
  • Task hazards not guarded properly
  • Other (horseplay, inattention....)
  • Stress demands
  • Lack of Process
• Methods
  • No or poor procedures
  • Practices are not the same as written procedures
  • Poor communication
• Management system
  • Training or education lacking
  • Poor employee involvement
  • Poor recognition of hazard
  • Previously identified hazards were not eliminated

Day 5

 Condition Based Maintenance

Data collection

Assessment

Correcton action

Inform

Follow up

Root cause failure

Failure modes and effects analysis

Failure mode, effects, and criticality analysis (FMECA)

Pre & Post Tests will be conducted

Case Studies, Group Exercises, Group Discussions, Last Day Review &Assessments will

be carried out.

………………………………….

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions