:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

PREPARE RCA FOR BASIC INCIDENT AND TAKE CORRECTIVE ACTIONS

Location

Vienna, Austria

Date

From Date: 04-Aug-2025
To Date: 08-Aug-2025

Duration

5 days

Language

ENGLISH

Discipline

MECHANICAL ENGINEERING

Introduction

The natural tendency of many individuals and organizations when presented with a problem is to jump to a solution, any solution. They do not systematically analyze 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 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 toward 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 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 Stress, 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

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 Problems

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

-LEARNING FROM FAILURE

-Performance monitoring

12. Preventive / Corrective Action (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 Reviews & Assessments will be carried out.

…………………………………………….

Certificate

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

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

Course Details