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Root Cause Failure Analysis for Industrial Plant and Equipment (Jakarta, Indonesia - March 2-4, 2020)

  • ID: 4871672
  • Training
  • March 2020
  • Location: Jakarta, Indonesia
  • 3 Days
  • Salvo Global
  • Training Dates: March 2-4, 2020
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The world-leading companies do not accept things going wrong in their business. They proactively focus on finding and stopping problems from affecting their operations. They investigate the root causes of an incident or problem and change their business processes to prevent the causes arising in the future.

The RCFA methodology is the problem-solving tool that many of them use to investigate, understand and halt problems. It is used at all levels in a business to solve all manner of problems. RCFA requires that you compile a knowledgeable team who investigate the problem situation and draw together relevant information and knowledge to stop it. The technique is used to address repetitive problems, to minimize risk in situations or scenarios, and when serious failures occur in order to understand why they happened and prevent them in future. It provides companies grand payback for the effort when the solutions are taken business-wide.

This RCFA training course is used by Companies to train a core of people in the Root Cause Failure Analysis (RCFA) process. This group becomes the resource to draw from when an RCFA is required. The group is also the pool from which RCFA Facilitators are drawn when RCFA teams are assembled.

The course is focused on using the powerful RCFA method and understanding the vital steps to be followed. Included in the programme is training on a range of investigative tools and problem-solving methods. The course also incorporates the correct use of the 5-Whys as an enabling tool for shopfloor people to investigate and solve minor defects and problems.

For rapid evolution and progress in your operation or company help your people develop RFCA skills, and the associated problem-solving techniques, so they have the capability to apply RCFA correctly. This course teaches people who work with problems how to use RCFA to find successful solutions to remove them. Once your company has the ability and confidence to use RCFA properly your people will make RCFA live every day in your operation and on the shop floor!

This 3-day intensive Masterclass provides the concepts needed to effectively perform industrial troubleshooting investigations. The course includes detailed design and troubleshooting guidelines, investigating techniques for system failures, which are needed to solve problems found in most production facilities.

Top Learning Objectives

  • Apply RCFA, 5 Why and FMEA methodologies in failure investigation
  • Think through the possibilities of physical root causes of a failure that go beyond a quick fix
  • Recognize the presence of event chains leading to a failure and analyze causes behind the causes
  • Verify or disprove contributing causes
  • Identify actions or recommendations that will avoid a repetition of the failure or problem investigated
  • Create a fault tree of an incident
  • Look for relevant evidence in a failure investigation or accident
  • Trace and identify the causes of equipment failures and industrial accidents
  • Spot high-risk situations and act to prevent problems
  • Understand the typical human factors involved in failures and accidents
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Registration begins at 08:00. Course sessions will start promptly at 08:30 and end at 16:30. There will be two short breaks at appropriate times for refreshments and lunch break will be from 12:30 to 13:30.

DAY 1 - SUCCESSFUL ROOT CAUSE FAILURE ANALYSIS (RCFA) PROGRAMS

HOW to MAKE RCFA PROGRAMS SUCCESSFUL

  • Improvement Driven not Problem Driven
  • Used at all levels in the company
  • Correctly apply Change Management
  • Focus on Defects instead of Catastrophe
  • Allocate Time and Resource
  • Top Management Endorsed Process
  • Follow the RCFA Process Steps
  • Take-up Process Ownership

THE RCFA TEAM FACILITATOR

  • Role of the Facilitator
  • Team Mix and Knowledge Mix
  • Running the RCFA Meeting
  • Cooperation Techniques
  • Using the Six Hats for New Perspectives
  • Facilitation Technique

ROOT CAUSE FAILURE ANALYSIS PROCESS TOOLS

  • Collecting Evidence
    • At Failure Site
    • Historical Records
    • Operating Records
    • Interviews
  • The 7 Standard Tools for Data Analysis
  • Investigation and Understanding
    • Process Mapping
    • Creative Disassembly
    • Fishbone Diagram
    • Activity 1 - Develop a Fishbone
    • Timeline Plots
    • Distribution Histogram
    • Failure Modes and Effects Analysis (FMEA)
    • FMEA at System Level and Component Level
    • Activity 2 - Apply FMEA at Component Level
  • Analysis and Identification
    • ‘Is-Is Not’ Table
    • Fault Tree Analysis (Why Tree)
    • Activity 3 - Develop a Simple Why Tree
    • ‘5 Whys’ Method
    • Activity 4 - Case Study - 5 Why Example
  • Corrective Action
    • Evaluation Table
    • Affinity Diagrams
    • Relationship Digraph

CASE STUDY EXAMPLE

  • Review a Successful RCFA and the Process and Methods Applied

GUIDED RCFA PRACTICE EXAMPLE

  • Activity 5 - Compete an RCFA under guidance

DAY 2 - IMPROVING PLANT AND EQUIPMENT RELIABILITY WITH RCFA

CHANGE MANAGEMENT OF RCFA IN AN ORGANISATION

  • Recognition and Cost of a Problem and its Impact
  • Create a Reliability Improvement Process that Involves Everyone
  • The Change Management Process
    • Senior Management Support and Management Champion
    • Force-Field Analysis
    • Involving and Getting Buy-in from the Right People
  • Solution Implementation
    • Developing Corrective Actions
    • Implementation, Resourcing and Time Plan
    • Project Management Methodology
  • Propagation
    • Business System Improvements

TAKING RELIABILITY IMPROVEMENTS COMPANY-WIDE

  • Permanently Capturing Improvements into Corporate Intelligence
  • Improving Business Processes and Standard Operating Procedures
  • Accuracy Controlled Operating Procedures for Failure Prevention
  • The Importance of Training People to Specifi c Quality Requirements
  • Activity 6 - Develop an Accuracy Controlled Procedure

PRACTICE EXAMPLE 1

  • Activity 7 - Perform an RCFA Applying Appropriate Methods from the Course
  • Develop an Implementation Plan for the Corrective Actions

PRACTICE EXAMPLE 2

  • Activity 8 - Develop a Plan to Perform an RCFA and Conduct the RCFA

DAY 3 - IMPLEMENTATION AND APPLICATION OF RCFA IMPLEMENTATION OF RCFA

  • Planning, preparation, and execution of RCA

ROOT CAUSE ANALYSIS APPLICATIONS

  • Reliability Centered Maintenance
  • FMECA
  • Compliance (Goals, values impacted, benchmarks and acceptance limits)
  • SIL (Safety goals impacted)
  • RBI Risk Based inspection
  • Continuous improvement Cost control Quality assurance and quality control; Reporting and sustainability
  • TPM

DEVELOP NEW PROGRAM REVIEW CURRENT OPERATIONS AND MAINTENANCE PRACTICES

  • PM routines and CMMS
  • RCM
  • REM Development, review and implementation of routine PM programs
  • Scheduling
  • Open Discussion and Questions

Close-out and Finish

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  • Thomas Nounezi Mr Thomas Nounezi,
    Founder & Lead Consultant ,
    TC-Uptimer Canada


    Thomas is a licensed reliability training specialist under the American Society for Quality Certified Reliability Engineer (CRE) with over 29 years’ industrial field and classroom experience in Operations Technology, engineering reliability analysis and implementation within power generation, food processing, rotating equipment; heavy duty industries, hydraulic pumps and valves. He holds a Master’s Degree in Mechanical Engineering majored in Materials Science and Engineering Reliability, Failure Analysis from University of Ottawa.

    His expertise includes analysing failure patterns for industrial assets and defining failure mode effects and mechanism and criticality analysis (FMECA). He uses the Plant Wellness Way (PWW) Physics of Failures Factors Analysis strategy management (POFFA) model to identify critical components and bad actors. He is also adept in developing management programs for operation, production, maintenance and design, and improvement and cost reduction programs.

    He has designed and developed training curriculums and contents to address identified skill gaps that hinder operations and processes benefits and timely deliveries. Based on reliability modelling and prediction, reliability design, testing and reliability management tools, he analysed, applied and documented tools and techniques including failure analysis, risk assessment and ranking, root cause analysis, failure modes effect and criticality analysis and HAZOP.

    He is passionate about reliability and continuous improvement, and committed in fostering PWW/LRS (Plant Wellness Way/ Lifetime Reliability Solutions) through failure elimination, reliability excellence, Total Productive Maintenance (TPM), Preventive, Predictive maintenance, CBM, and RCM strategies. His training helped many industrial organizations to save great money and time as their people became aware and advised to take ownership and perform value-creating operation and repair decisions, accurate testing, data collection, and analysis, failures elimination strategies.

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This course is very relevant to technical engineers and professionals who handle and are responsible for their organisations’ maintenance; as well as the overall smooth operations and processes of their organizations’ plants and machineries. These include Superintendents, Managers, Supervisors, Team Leaders, Heads of Department, Engineers, Foreman, Planners, Directors of the following departments:

  • Maintenance
  • Mechanical
  • Preventive Maintenance
  • Manufacturing
  • Predictive Maintenance
  • Physical Asset Management
  • Production
  • Project
  • Quality Management
  • Reliability
  • Process
  • Control
  • Instrumentation
  • Engineering
  • Operations
  • Plant
  • Transmission
  • Automation
  • Inspection

From the following Industries:

  • Mining
  • Manufacturing
  • Power & Utilities
  • Engineering
  • Oil & Gas
  • Petrochemicals
  • Chemicals
  • Pharmaceuticals
  • Food & Beverage
  • Automotive
  • Construction
  • Aviation
  • FMCG
  • Telecommunications
  • Support Services
  • Pulp and Paper
  • Agriculture
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ADDRESS

Jakarta
Indonesia

Venue to be announced shortly.

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