Root Cause Failure Analysis, Corrective and Preventive Maintenance

The programme

Programme overview

Every organization establishes vital defenses—from robust maintenance and operating procedures to comprehensive training—to mitigate the risk of failure. Despite these efforts, unexpected events can breach defenses, leading to significant undesirable outcomes. Compounding this, chronic, low-level failures, often unnoticed individually, create enormous cumulative costs. Addressing these persistent issues offers a profound opportunity for performance improvement. Root Cause Analysis (RCA) is a structured process to determine what must be done to prevent the recurrence of undesirable outcomes. Applied correctly, RCA identifies the physical mechanisms of failure, the human actions or inactions involved, and the contributing organizational factors. Uncovering these root causes empowers organizations to generate and implement targeted solutions, strengthening defences and reducing recurrence risk.

Who should attend

Who is this programme for?

The Root Cause Failure Analysis and Corrective Preventive Maintenance course is suitable for a wide range of people that are involved with the maintenance and operation of physical assets. I is important that people that lead or participate in RCA and those that lead the development of maintenance tactics and a reliability programme for the physical assets of the organisation should attend. Typical delegates would include:

• Reliability engineers
• Maintenance planners
• Maintenance supervisors
• Technicians, craftsmen and artisans
• Operations supervisors

Learning outcomes

What you will learn

This course on Root Cause Analysis of Failure aims to equip participants with the essential knowledge and practical skills required to systematically investigate undesirable outcomes, transforming reactive responses into proactive, data-driven improvements. By delving into the underlying causes of equipment failures and operational inefficiencies, the program empowers individuals and organizations to implement sustainable solutions, enhance reliability, optimize costs, and foster a culture of continuous learning and resilience.

The objectives of this Root Cause Analysis of Failure Course are to:

• Understand the Spectrum of Failures: Develop a comprehensive understanding of nature, risks, and various causes of equipment failures, from unanticipated catastrophic events to chronic, high-frequency issues, and their contribution to business success.
• Master Proactive Risk Mitigation: Acquire techniques to proactively manage equipment reliability and risk, focusing on upgrading maintenance and operating procedures, skills, and organizational practices to prevent recurrence.
• Leverage Failure Data for Insight: Learn how to effectively collect, prepare, and analyze failure data, distinguishing between chronic and intermittent issues, and assessing the cost-benefit of conducting a root cause analysis.
• Apply Systematic RCA Techniques: Gain practical proficiency in various Root Cause Analysis methodologies, including Ishikawa (Fishbone) diagrams, the “5 Whys,” and rigorous RCA processes, along with the preparation and organization required for effective analysis.
• Develop and Implement Actionable Solutions: Learn to apply rigorous RCA to real-world scenarios, develop comprehensive implementation action plans, and understand how to track their execution.
• Quantify Improvement and Drive Organizational Learning: Understand how to calculate the Return on Investment (ROI) for RCA initiatives, ensuring that findings translate into tangible value, fostering continuous improvement and organizational commitment beyond technical analysis.

Explore the programme

Detailed programme outline

MODULE 1

The Risk, Nature & Causes of Equipment Failures

• The contribution of effective maintenance to business success
• The risk of unanticipated equipment failure
• Proactive risk and reliability management
• Functional failures and failure modes
• Damage mechanisms cause and effects

MODULE 2

Taking Control of Equipment Reliability & Risk

• 2.1Risk mitigation options and techniques
• 2.1.1 Implement robust programmed maintenance
• 2.1.2 Upgrade maintenance procedures / skills / practices
• 2.1.3 Upgrade operating procedures / skills / practices
• 2.1.4 Upgrade organisational procedures / skills / practices
• 2.2 Error-proof equipment, processes and procedures
• 2.3 International standards relating to RCA

MODULE 3

Failure Reporting & Analysis

• Failure data requirements
• Failure data preparation
• Failure data analysis techniques
• Distinguishing between chronic and intermittent failure
• Cost benefit analysis of doing a root cause analysis

MODULE 4

RCA Techniques & Preparation for the Analysis

• Facilitator selection and appointment
• Team composition
• Preparing and organising the analysis
• Setting objectives
• Evidence collection and preservation
• Record of meetings and proceedings
• RCA technique selection and training
• Ishikawa (Fishbone) cause and effect diagram
• Five-whys
• Fault Tree Analysis
• Troubleshooting matrices
• Rigorous RCA

MODULE 5

Practical Application of Rigorous RCA

• Case study using a generic example
• Client specific failure example
• Develop implementation action plan
• Track implementation
• Calculate RCA Return on Investment

Learning approach

How you will learn

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.– Course Material: Access well-crafted supporting resources.– Group Work: Collaborate on discussions and case studies for practical insights.– Workshops & Role-Play: Participate in immersive, scenario-based activities.– Practical Application: Focus on applying theoretical knowledge in real situations.– Post-Training Support: Receive extensive support after training for skill implementation.

Discuss your requirements

Dates, duration & arrangements

Contact Ratomac to confirm dates, duration, delivery format, entry requirements and any applicable assessment or certification before booking.