COURSE OVERVIEW:

Machinery Root Cause Failure Analysis (RCFA) is a structured, investigative process used to identify the underlying reasons for mechanical equipment failure. This course moves beyond superficial symptom-fixing to uncover the physical, human, and latent causes of machinery distress. Participants will learn how to preserve evidence after a breakdown and apply rigorous analytical frameworks to ensure that once a machine is repaired, the failure does not recur.

The scope of this training involves a deep dive into the forensic examination of mechanical components such as bearings, gears, seals, and shafts. Coverage includes the use of various logic-based methodologies, including the "5 Whys," Fishbone Diagrams, and Fault Tree Analysis, tailored specifically for complex rotating assets in the industrial sector. Emphasis is placed on the metallurgical and mechanical indicators of stress, fatigue, and environmental degradation that provide the evidence for a technical diagnosis.

Furthermore, the course addresses the organizational and management factors that often contribute to asset failure, such as poor maintenance procedures, inadequate spare parts quality, or operational errors. Trainees will develop the skills to facilitate an RCFA team, document findings into actionable reports, and track the effectiveness of implemented solutions. By mastering these investigative techniques, engineers can shift the plant culture from one of constant firefighting to a high-reliability environment.

COURSE OBJECTIVES:

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

• Define the primary differences between failure symptoms and root causes.
• Implement a systematic evidence preservation protocol following an asset failure.
• Apply Fault Tree Analysis (FTA) to map out complex mechanical failure paths.
• Utilize the "5 Whys" technique to uncover latent and organizational root causes.
• Identify different types of fatigue and overload patterns on fractured surfaces.
• Recognize the signatures of abrasive, adhesive, and corrosive wear on bearings.
• Facilitate a cross-functional RCFA team to ensure diverse technical perspectives.
• Distinguish between physical causes, human errors, and systemic latent causes.
• Interpret vibration, oil analysis, and SCADA data as historical evidence.
• Develop cost-effective recommendations to eliminate identified failure modes.
• Write professional RCFA reports that communicate technical findings to management.
• Establish a tracking system to verify the long-term success of corrective actions.
• Utilize specialized software and tools for failure mapping and documentation.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Maintenance Managers, Rotating Equipment Specialists, and Senior Technicians involved in the long-term reliability of industrial assets.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.