COURSE OVERVIEW:

The Failure Reporting and Corrective Action System (FRACAS) is a sophisticated closed-loop process designed to drive continuous improvement in asset performance. This course provides a technical framework for identifying systemic equipment failures and implementing engineering changes that prevent recurrence. It focuses on the transition from simply fixing broken parts to establishing a rigorous organizational memory that treats every failure as a valuable data point for long-term reliability.

The scope of this training involves the integration of maintenance data collection with deep analytical methodologies. Participants will explore the mechanics of building a functional FRACAS, including the design of failure codes, the establishment of cross-functional review boards, and the validation of corrective actions. The curriculum emphasizes the strategic importance of high-quality technical history in the Computerized Maintenance Management System (CMMS) and how to transform raw maintenance logs into actionable reliability intelligence.

Coverage includes the application of Root Cause Analysis (RCA) within the FRACAS cycle, the use of statistical tools to identify failure trends, and the management of "Bad Actor" lists. Attendees will learn how to quantify the financial benefits of eliminated failures and how to communicate these successes to executive leadership. By the end of this program, participants will be equipped to lead a cultural shift toward a "zero-defect" mentality, ensuring that every industrial failure leads to a permanent improvement in plant design or maintenance strategy.

COURSE OBJECTIVES:

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

• Implement a comprehensive five-stage FRACAS cycle within an industrial environment.
• Standardize failure reporting protocols to ensure data consistency and accuracy.
• Establish a multi-disciplinary Failure Review Board (FRB) to oversee corrective actions.
• Distinguish between sporadic failures and chronic "bad actor" equipment issues.
• Utilize Pareto analysis to prioritize high-impact reliability improvement projects.
• Apply advanced Root Cause Analysis (RCA) techniques to close the loop on failures.
• Define specific Failure, Cause, and Remedy codes for various asset classes.
• Validate the effectiveness of implemented engineering and procedural changes.
• Track the Mean Time Between Failures (MTBF) as a primary metric for FRACAS success.
• Integrate FRACAS workflows seamlessly with existing CMMS and EAM platforms.
• Quantify the Return on Investment (ROI) of reliability improvements for management.
• Manage the cultural change required to foster a transparent reporting environment.

TARGET AUDIENCE:

This course is essential for Reliability Engineers, Maintenance Managers, Asset Managers, CMMS Administrators, Operations Supervisors, and Quality Assurance Specialists involved in industrial performance improvement.

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.