Machinery Root Cause Failure Analysis (RFCA)

Objectives

o   Execute system approach of failure analysis and troubleshooting and identify the causes of machinery failure and their contributing factors which are often overlooked

o   Gain an in-depth knowledge on metallurgical failure analysis methodology as illustrated by failure analysis of bolted joints and shafts

o   Perform machinery component analysis and reliability improvement by recognizing redesigned opportunities, bearings in distress, coupling failure avoidance opportunities and mechanical seal problems

o   Develop an understanding of continuous reliability improvement and the various approaches to optimized lubrication for pumps and electric motors

o   Apply and gain an understanding on vendor selection and reliability review methods through centrifugal pump selection & compressor reliability review examples and perform troubleshooting of pumps and centrifugal compressors

o   Recognize the application of vibration analysis from a management perspective by studying specific machinery problems, as well as monitoring and analysis methods

o   Identify and carry out a structured problem-solving sequence after careful perusal of problem-solving elements, cause analysis, action generation, decision making and planning for change

o   Perform formalized failure reporting using actual cases such as high-speed pump and bearing failures

o   Determine the process of examination of failed components such as bearings, gears, mechanical seals and others

o   List the elements of centrifugal pump failure reduction programs taking into account the process and the mechanical & technical interactions

o   Double the productivity of their maintenance employees, and

o   Reduce their total maintenance cost by up to 30%

o   Develop and implement a sustainable world-class maintenance strategy

o   Perform a systematic Root Cause Failure Analysis

o   Develop an improved understanding of numerous maintenance environment variables, and of the relationships between them

o   Optimize these relationships in line with the TRIZ contradiction principle

o   Understand, audit and optimize your maintenance process

o   Apply and gain in-depth knowledge on safety root cause analysis

o   Identify the common causes of incidents and enumerate the different various types of accidents to investigate

o   Determine the link between investigation and risk assessment and acquire knowledge on how to predict possible incidents using reactive and proactive methods

o   Discuss the framework for incident investigation and analysis such as the relationship between the accidents and incidents, link between reactive and pro-active, management system failure and root causes for accidents

o   Employ the root cause analysis (RCA) techniques and differentiate between cause tree analysis (CTA) and fault tree analysis (FTA)

o   Implement the principle stages of an accident investigation on planning and how to counteract investigator bias and mindset

o   Apply structured data collection such as getting information, preparing incident report and statement from the incident scene

o   Carry out investigating, interviewing, and storyboarding using the latest techniques for incident investigations

o   Practice the latest incident investigation procedures, forms, and documentation through practical exercises, application-based case studies, and workshops designed to reflect and employ the root cause analysis (RTA)

o   Understand the use and application of generic problem-solving techniques

o   Cascade the principles and benefits of the program to other employees

Outline

Strategic Maintenance Issues & Latest Research

·        Introduction to World Class Manufacturing

·        The SQC Planning Model

·        The Strategic Role of the maintenance discipline in the context of organizational excellence and continuous improvement

·        Maintenance Problems and Objectives (Individual Exercise)

·        The QMS Maintenance Complexity Model

·        The Six Schools of modern Maintenance Science

·        The World Class Maintenance Process (Group Exercise)

·        Maintenance Maturity Indexing

·        The Maintenance Cost Ratio

Sustainable Maintenance Performance Improvement 

·        The MVA Model (incl. Group Coding Exercises; Experience; Pay-for-Performance 😉

·        Cross Referencing Maintenance Objectives (Group Exercise)

·        ‘Your Maintenance Costs are too high!’

·        Classification of Maintenance Work

·        Reverse Risk Analysis (DDC + Force Field Analysis + CPA)

Sustainable Maintenance Performance Improvement 2

·        Data / Knowledge Base

·        Accuracy and Availability of Data / Cost relationship

·        The Four critical stages of Data Maturity

·        Logical Critical Thinking vs. Creative Lateral Divergent Thinking

·        24 Thinking Types

·        Maintenance Strategy Development and Implementation

·        Standard Pitfalls for Maintenance Improvement Initiatives

·        The HR Stratification Model for Multi-Skilling

·        Nine Generic Problem Solving Techniques

·        Other Problem Solving Techniques

·        The QMS Root Cause Failure Analysis Methodology

·        Case Study: Bell helicopter main bearing failure

·        Case Study: Broken chain links

Root Cause Analysis

Who Should Attend ?

·        Engineering and Technical Professionals and Supervisors from any industry

·        Maintenance Planners and Coordinators

·        Operations and Manufacturing Professionals and Supervisors

·        Foremen and Team leaders

·        Plant Engineers and Maintenance System Professionals

·        Section Engineers and Planners