Maintenance and Engineering

Root Cause Failure Analysis for Engineers

Repeated failures show that underlying causes have not been addressed. This course teaches root cause failure analysis for engineering assets: preserving evidence, failure mechanisms, physical, human and latent causes, analysis tools, metallurgical and fractography basics, corrective actions and verifying effectiveness.

5 days Classroom or live online English

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Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Replacing failed parts without understanding why they failed leads to repeat breakdowns. You will learn to eliminate failures at their source.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Failure case studies, analysis tool practice, evidence handling exercises and team investigations.

Course objectives

What you'll take away.

By the end of this course, participants will be able to:

Explain the principles of root cause failure analysis
Preserve failure evidence correctly
Identify failure mechanisms in components
Apply structured analysis tools
Distinguish physical, human and latent causes
Implement and verify corrective actions

Target audience

Who should attend.

This course is suitable for:

Reliability and maintenance engineers
Mechanical and process engineers
Maintenance supervisors
Plant engineers
Quality engineers

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Failure investigation
Evidence handling
Failure mechanisms
Causal analysis
Corrective action

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1RCFA Principles

09:00–10:08Why failures repeat
10:08–11:00Investigation triggers
11:00–11:30Coffee break
11:30–11:45Investigation triggers (continued)
11:45–12:53Team roles
12:53–14:00Exercise

Day 2Evidence

09:00–10:08Preserving parts and data
10:08–11:00Interviews
11:00–11:30Coffee break
11:30–11:45Interviews (continued)
11:45–12:53Timelines
12:53–14:00Workshop

Day 3Failure Mechanisms

09:00–10:08Fatigue, wear and corrosion
10:08–11:00Overload
11:00–11:30Coffee break
11:30–11:45Overload (continued)
11:45–12:53Fractography basics
12:53–14:00Case study

Day 4Analysis Tools

09:00–10:08Logic trees
10:08–11:00Fishbone and 5 Whys
11:00–11:30Coffee break
11:30–11:45Fishbone and 5 Whys (continued)
11:45–12:53Human and latent causes
12:53–14:00Exercise

Day 5Corrective Actions

09:00–10:08Action selection
10:08–11:00Verification
11:00–11:30Coffee break
11:30–11:45Verification (continued)
11:45–12:53Sharing lessons
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon certificate of attendance. Smart Horizon programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

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