COURSE OVERVIEW:

Root Cause Failure Analysis (RCFA) for mechanical failures is a systematic engineering process designed to uncover the fundamental reasons behind component or system breakdowns. Unlike traditional troubleshooting, which often focuses on restoring operation by addressing symptoms, RCFA seeks to understand the "why" behind the physical damage. By applying a structured investigative approach, organizations can move from a "fail-and-fix" cycle to a "predict-and-prevent" strategy, ultimately enhancing the reliability and safety of industrial infrastructure.

The scope of this course involves a deep dive into the physical, human, and latent roots of mechanical degradation. Participants will learn to analyze a wide array of failure modes, including fatigue, ductile and brittle fractures, wear, and corrosion. The curriculum emphasizes the importance of preserving the "scene of the crime" and collecting high-quality evidence, ranging from fractured surfaces and metallurgical samples to digital data logs and maintenance histories. This holistic view ensures that the analysis accounts for environmental stressors and operational deviations that contribute to mechanical fatigue.

Throughout the program, the coverage extends to the practical application of logical tools such as Fault Tree Analysis, Fishbone Diagrams, and the "5 Whys" technique within a mechanical context. Engineers and technicians will develop the skills to synthesize complex technical data into actionable recommendations. By implementing the lessons from this course, participants will be equipped to eliminate repetitive failures, optimize maintenance intervals, and significantly reduce the risks associated with catastrophic mechanical equipment loss.

COURSE OBJECTIVES:

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

1. Define the fundamental principles of Root Cause Failure Analysis in mechanical systems.
2. Distinguish between physical, human, and latent root causes of equipment failure.
3. Conduct a systematic on-site investigation following a mechanical breakdown.
4. Interpret various fracture surface topographies to identify loading conditions.
5. Identify the visual signatures of high-cycle and low-cycle fatigue.
6. Analyze the impact of material selection and heat treatment on component longevity.
7. Apply the "5 Whys" technique to drill down into organizational system flaws.
8. Construct a Logic Tree or Fault Tree to map out complex failure paths.
9. Evaluate the role of lubrication and friction in mechanical wear failures.
10. Assess the influence of residual stresses and manufacturing defects on parts.
11. Develop evidence-based reports that clearly communicate findings to management.
12. Formulate effective corrective and preventive actions to stop failure recurrence.
13. Utilize basic metallurgical tools and non-destructive testing for failure verification.
14. Integrate RCFA results into a comprehensive Reliability Centered Maintenance program.

TARGET AUDIENCE:

This course is intended for Mechanical Engineers, Maintenance Supervisors, Reliability Professionals, Plant Foremen, and Asset Management Specialists involved in industrial operations.

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.