UNDERSTANDING RCFA COMPLETELY
“Mastering Root Cause Failure Analysis Techniques to Prevent Recurrence and Drive Operational Reliability”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 21 – 25 Sep 2026 | London, UK | USD 3495 per delegate |
Course Introduction
Root Cause Failure Analysis (RCFA) is a structured method of problem-solving used to identify the underlying causes of equipment failures, process upsets, and recurring operational issues. It plays a crucial role in enhancing asset reliability, reducing downtime, and improving safety. Understanding RCFA completely means going beyond the basics to apply proven techniques in a consistent, evidence-based manner across complex industrial environments.
This intensive 5-day course delivers comprehensive, hands-on training in the principles, tools, and execution of RCFA. Participants will learn how to lead investigations, gather and interpret data, build logical cause-effect chains, and implement sustainable corrective actions that prevent future failures.
Course Objectives
By the end of this course, participants will be able to:
• Understand the philosophy, principles, and objectives of RCFA
• Apply proven RCFA tools including 5 Whys, fault tree, and cause-effect mapping
• Lead and facilitate structured investigations across technical disciplines
• Collect physical, operational, and historical evidence to support conclusions
• Design effective and sustainable corrective and preventive actions
Key Benefits of Attending
• To reduce unplanned equipment failures and costly downtime
• To strengthen problem-solving and analytical thinking across teams
• To comply with regulatory and internal reliability improvement mandates
• To build a consistent methodology for investigating failures
• To improve organizational learning and safety culture
Intended Audience
This program is designed for:
• Maintenance and reliability engineers
• Operations and plant managers
• Quality assurance and safety personnel
• Asset management and root cause analysts
• Anyone involved in failure investigations or process improvement initiatives
Individual Benefits
Key competencies that will be developed include:
• Structured problem solving and critical thinking
• Evidence-based analysis and causal mapping
• Facilitation of multidisciplinary RCFA teams
• Technical writing and reporting of findings
• Development of SMART corrective and preventive actions
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved reliability and availability of critical assets
• Lower maintenance costs and extended equipment life cycles
• Enhanced safety and incident prevention
• More efficient and standardized investigation procedures
• Strengthened continuous improvement and knowledge retention
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – RCFA philosophy, reliability frameworks, and global standards
• Case Studies – Real-world failures and how they were investigated
• Workshops – RCFA tool application, evidence mapping, and team exercises
• Peer Exchange – Sharing cross-industry lessons and common pitfalls
• Tools – RCFA templates, investigation forms, causal factor charts, and action plans
Course Outline
Detailed 5-Day Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Foundations of RCFA and Failure Understanding
- Module 1: Introduction to RCFA Principles (07:30 – 09:30)
• Why failures recur and how RCFA addresses root causes
• The difference between symptoms, causes, and root causes
• Types of failure modes: mechanical, human, process, and system - Module 2: Failure Data Collection and Evidence Handling (09:45 – 11:15)
• What data to collect and when
• Evidence handling and documentation
• Failure scene preservation and interview techniques - Module 3: RCFA Process Framework and Roles (11:30 – 01:00)
• Planning and scoping investigations
• RCFA team structure and responsibility assignment - Module 4: Workshop – Develop an RCFA Charter (02:00 – 03:30)
• Define the scope, timeline, and team for a case scenario
Day 2: RCFA Tools and Techniques – Part I
- Module 1: 5 Whys and Cause Mapping (07:30 – 09:30)
• Simple root cause identification method
• When and how to apply it effectively - Module 2: Fishbone (Ishikawa) and Causal Factor Charts (09:45 – 11:15)
• Categorizing causes into systems, procedures, people, and equipment
• Building visual cause diagrams - Module 3: Fault Tree Analysis (FTA) Basics (11:30 – 01:00)
• Understanding top events and logic gates
• Applying FTA to critical failures - Module 4: Group Exercise – Applying Cause Mapping (02:00 – 03:30)
• Hands-on case exercise using real-world failure
Day 3: RCFA Tools and Techniques – Part II
- Module 1: Timeline Construction and Event Sequencing (07:30 – 09:30)
• Chronological analysis of failure evolution
• Identifying delays, decisions, and deviations - Module 2: Human and Organizational Factors (09:45 – 11:15)
• Latent vs. active failures
• Influences of training, supervision, and culture - Module 3: Verification of Root Causes (11:30 – 01:00)
• Testing logic and avoiding assumptions
• Using evidence to support conclusions - Module 4: Workshop – Full RCFA on Sample Case (02:00 – 03:30)
• Team-based failure investigation simulation
Day 4: Corrective and Preventive Actions (CAPA)
- Module 1: Designing Effective CAPA (07:30 – 09:30)
• From root cause to solution
• Preventing recurrence and addressing systemic risk - Module 2: CAPA Implementation and Ownership (09:45 – 11:15)
• Assigning responsibilities and follow-through
• Tracking KPIs and verifying results - Module 3: Reporting RCFA Results (11:30 – 01:00)
• Structuring RCFA reports for clarity and action
• Presenting findings to leadership and stakeholders - Module 4: Group Exercise – Develop a CAPA Plan (02:00 – 03:30)
• Translate investigation results into actions
Day 5: Integration, Review, and Case Applications
- Module 1: Embedding RCFA into Organizational Practice (07:30 – 09:30)
• Linking RCFA with RCM, TPM, and safety systems
• Building an RCFA culture and database - Module 2: Auditing and Improving RCFA Effectiveness (09:45 – 11:15)
• Measuring impact and identifying gaps
• Periodic review and knowledge sharing - Module 3: Final Project and Presentations (11:30 – 01:00)
• Teams present full RCFA of assigned case - Module 4: Wrap-Up, Feedback & Certification (02:00 – 03:30)
• Course debrief, Q&A, and certificate distribution
Certification
Participants will receive a Certificate of Completion in Root Cause Failure Analysis (RCFA), verifying their ability to conduct structured, evidence-based investigations and implement corrective actions to prevent failure recurrence.