COURSE OVERVIEW:

Reliability begins with a deep understanding of how things fail. This course focuses on "Failure Modes and Effects Analysis" (FMEA), a systematic and proactive tool used to identify potential failure points in a system before they occur. It provides participants with a disciplined methodology to evaluate the impact of these failures on safety, production, and cost, allowing them to develop targeted maintenance strategies that prioritize the most critical risks.

The scope of this training involves the step-by-step execution of an FMEA, from system boundary definition to the calculation of Risk Priority Numbers (RPN). Participants will learn how to distinguish between a "Failure Mode" (what happened), a "Failure Cause" (why it happened), and a "Failure Effect" (the consequence). The course emphasizes the practical application of FMEA findings to optimize Preventive Maintenance (PM) tasks and Predictive Maintenance (PdM) intervals, ensuring that every maintenance action is linked to a specific failure risk.

Coverage includes the use of FMEA for both "Design" (DFMEA) and "Process/Maintenance" (PFMEA/MFMEA). Attendees will explore how to facilitate FMEA workshops, engage cross-functional teams, and manage the resulting data within a CMMS or RCM software environment. By the end of this course, participants will be able to lead FMEA initiatives that significantly reduce unplanned downtime, eliminate "maintenance-induced" failures, and improve the overall reliability of their plant’s infrastructure.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the purpose and history of FMEA in reliability engineering.
• Identify and document "Failure Modes," "Causes," and "Effects" correctly.
• Facilitate a cross-functional FMEA workshop for critical plant assets.
• Calculate and interpret the "Risk Priority Number" (RPN).
• Apply FMEA to identify "Single Points of Failure" in complex systems.
• Use FMEA results to optimize and justify Preventive Maintenance tasks.
• Link PdM technologies to specific failure modes identified in the analysis.
• Differentiate between Design FMEA and Maintenance/Process FMEA.
• Implement a structured "Action Plan" to mitigate high-risk failure modes.
• Integrate FMEA data into the CMMS for better failure code management.
• Track the effectiveness of maintenance changes using "Post-FMEA" audits.
• Sustain FMEA as a "Living Document" for continuous reliability improvement.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Maintenance Managers, Maintenance Planners, Mechanical/Electrical Engineers, and Senior Technicians involved in asset strategy development.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.