Course Details

Objective

This course provides clarification of regulatory expectations and guidance and the essential skills necessary to ensure effective and efficient investigations. Topics will examine each step of the investigation process from failure identification and notification through documentation. Participants will practice root cause analysis techniques and identify corrective and/or preventive actions towards successful remediation.

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

• Dealing 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

Content

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.

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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