:: 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: 05-Aug-2024
To Date: 09-Aug-2024

Duration

5 Days

Language

English

Discipline

Introduction

The natural tendency of many individuals and organisations when presented with a prob lem 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 Essential skills necessary to ensure effective and efficient investigations. Topics will examine each step of the investigation process from failure identification and notifica tion through documentation.

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

Course Details