COURSE OVERVIEW:

The core meaning of this course is the practical application of Root Cause Failure Analysis (RCFA) to eliminate chronic equipment failures and safety incidents. RCFA is the investigative heart of any reliability program, moving organizations away from "Quick Fixes" toward "Permanent Solutions." This workshop-style course focuses on the rigorous selection and use of specific analytical tools to peel back the layers of a failure until the underlying systemic, human, and physical causes are revealed.

The scope of this training involves the end-to-end investigative process, from initial evidence preservation and "Data Gathering" to the implementation and tracking of corrective actions. Participants will gain hands-on experience with the three most versatile RCFA tools: 5-Why (for simple to moderate issues), Fishbone/Ishikawa (for identifying all possible contributing factors), and Fault Tree Analysis (for complex, multi-event system failures). The curriculum emphasizes the "Logic of Evidence," ensuring that no conclusion is reached without a verifiable physical or data-driven basis.

Coverage includes the human element of RCFA, such as "Interviewing Techniques" and managing "Cognitive Bias" during the investigative process. Attendees will explore how to write compelling "RCFA Reports" that gain management approval and how to utilize the "Lesson Learned" feedback loop to prevent similar failures across different plant sites. By the end of this course, participants will be able to facilitate an RCFA team, lead a technical investigation, and deliver actionable recommendations that provide a measurable return on investment through improved asset uptime.

COURSE OBJECTIVES:

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

• Define the differences between "Physical," "Human," and "Latent" root causes.
• Implement a standardized "RCFA Workflow" from incident to resolution.
• Master the "5-Why" technique to identify systemic triggers for simple failures.
• Construct "Fishbone (Ishikawa) Diagrams" to categorize contributing factors.
• Build complex "Fault Tree Analyses" (FTA) for multi-path system failures.
• Utilize "Evidence Collection" protocols (Photos, Logs, Samples, Interviews).
• Facilitate a multidisciplinary "RCFA Investigation Team."
• Identify "Latent Root Causes" within organizational policies and procedures.
• Develop "SMART" (Specific, Measurable, Achievable, Relevant, Time-bound) recommendations.
• Write clear and professional "RCFA Investigation Reports."
• Track the "Effectiveness" of implemented corrective actions.
• Communicate "Lessons Learned" to prevent failure recurrence site-wide.

TARGET AUDIENCE:

This course is essential for Maintenance Supervisors, Reliability Engineers, HSE Specialists, Operations Coordinators, and Technical Leads.

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.