ROOT CAUSE FAILURE ANALYSIS

TRAINING OBJECTIVES

Provide the knowledge and skills necessary to facilitate and understand how to maximize the result of your RCA program. Applying ROOT CAUSE ANALYSIS to solve all types of problems. you can investigate errors, defects, failures, losses, outages and incidents in a wide variety of industries The course is designed to enable the candidate to work out an investigation and document the root cause of all the problems relating to equipment and human error and equipment failure that results in loss of productivity, accident and damage.

DESCRIPTION SUBJECTS :

1 Failure of Machines and Inspection Based Failure Analysis

• Failure analysis tools
• Failure Mode & Effects Analysis
• Root Cause Analysis

2 Causes of Machinery Failure –

• Industrial failure
• Introduction
• Wear mechanisms, fatigue, fretting, and corrosion and electrolytic.
• Equipment, failure and maintenance data
• Causes and implication
• Hazards
• Thermal and chemical stability data and hazardous effects of inadvertent mixing of different material

3. General principles of root cause analysis

General process for performing and documenting an RCA-based Corrective Action

• Define the problem.
• Gather data/evidence.
• Ask why and identify the true root cause associated with the defined problem.
• Identify corrective action(s) that will prevent recurrence of the problem (your 100 year fix).
• Identify effective solutions that prevent recurrence, are within your control, meet your
• goals and objectives and do not cause other problems.
• Implement the recommendations.
• Observe the recommended solutions to ensure effectiveness.
• Variability Reduction methodology for problem solving and problem avoidance.

4. Root cause analysis techniques

• desired.
• Failure mode and effects analysis
• Fault tree analysis
• 5 Whys
• Ishikawa diagram, also known as the fishbone diagram or cause-and-effect diagram.
• Pareto analysis
• RPR Problem Diagnosis –

5. Basic elements of root cause

• Materials

1. Defective raw material
2. Wrong type for job
3. Lack of raw material

• Machine / Equipment

1. Incorrect tool selection
2. Poor maintenance or design
3.  Poor equipment or tool placement
4. Defective equipment or tool

• Environment

1. Orderly workplace
2. Job design or layout of work
3.  Surfaces poorly maintained
4. Physical demands of the task
5. Forces of nature

• Management

1. No or poor management involvement
2. Inattention to task
3.  Task hazards not guarded properly
4. Other (horseplay, inattention....)
5. Stress demands
6. Lack of Process

• Methods

1. No or poor procedures
2. Practices are not the same as written procedures
3. Poor communication

• Management system

1. Training or education lacking
2. Poor employee involvement
3. Poor recognition of hazard
4. Previously identified hazards were not eliminated

6. Condition Based Maintenance

• Data collection
• Assessment
• Correcton action
• Inform
• Follow up
• Root cause failure
• Failure modes and effects analysis
• Failure mode, effects, and criticality analysis (FMECA)
• How Root Cause Analysis Works

PARTICIPANT

This program is designed for Supervisors, Team Leaders, Engineers and Managers in Maintenance, Engineering and Production from all industries.

INSTRUCTUR

Ir. Gregorius Harjanto & Team

PRICE

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