COURSE OVERVIEW:

The fundamental meaning of this course is the systematic engineering investigation of equipment failures to eliminate their recurrence through the identification of systemic and physical root causes. RCFA is not merely a problem-solving tool; it is a cultural discipline that shifts an organization from "Repair-Oriented" to "Reliability-Oriented" thinking. This curriculum provides the technical protocols required to move past the "Physical Symptom" of a failure to uncover the "Latent Human and Systemic" deficiencies that allowed the failure to occur.

The scope of this training involves the mastery of diverse analytical tools, including 5-Why, Fishbone (Ishikawa) Diagrams, and Fault Tree Analysis (FTA). Participants will learn the rigorous process of "Evidence Preservation," which involves the collection and forensic analysis of failed components, digital logs, and witness statements. The course emphasizes the transition from a "Blame-Based" culture to a "Learning-Based" environment where failures are viewed as high-value data points for future reliability improvement.

Coverage includes the development of "SMART" recommendations, the calculation of "Cost of Unreliability," and the implementation of a "Defect Elimination" program. Attendees will examine how to track the effectiveness of corrective actions and how to communicate complex technical findings to executive leadership to secure funding for redesigns. By the end of this program, participants will be able to lead multidisciplinary RCFA teams that deliver measurable improvements in Mean Time Between Failures (MTBF) and overall plant profitability.

COURSE OBJECTIVES:

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

• Define the technical differences between physical, human, and latent root causes.
• Implement a standardized "RCFA Workflow" from incident trigger to closeout.
• Master the "5-Why" technique to identify systemic organizational triggers.
• Construct "Fishbone Diagrams" to categorize all possible failure contributing factors.
• Build "Fault Tree Analyses" (FTA) for complex, multi-path system collapses.
• Utilize "Evidence Collection" protocols to preserve digital and physical failure data.
• Facilitate a multidisciplinary "RCFA Investigation Team" session effectively.
• Conduct "Cognitive Interviews" with operators and maintainers to reconstruct events.
• Develop "SMART" recommendations that address systemic latent root causes.
• Calculate the "Total Cost of Failure" to prioritize investigations and resources.
• Track the "Effectiveness" of implemented corrective actions over time.
• Communicate "Lessons Learned" site-wide to prevent similar failure patterns.

TARGET AUDIENCE:

This course is designed for Maintenance Engineers, Reliability Specialists, Operations Supervisors, HSE Officers, and Technical Asset Managers.

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.