Root Cause Failure Analysis Equipment
Membekali peserta dengan keterampilan praktis dan alat analisis yang dibutuhkan untuk melaksanakan *Root Cause Failure Analysis* (RCFA) secara terstruktur pada peralatan industri, mengidentifikasi mekanisme kegagalan teknis maupun sistemik, mengevaluasi faktor-faktor penyebab, serta menyusun tindakan korektif dan pencegahan yang berkelanjutan sesuai dengan prinsip keandalan dan integritas aset.
F. Reservoir Engineering Course/Petroleum Engineering
3 Hari
Terampil
Classroom + Field Trip
Setelah mengikuti kursus ini, peserta mampu:
- Apply structured RCFA methodologies
- Identify mechanical and systemic failure mechanisms
- Collect and analyze investigation data
- Distinguish symptoms from root causes
- Recommend sustainable technical and organizational solutions
- Integrate RCFA into reliability improvement programs
Hari 1 – Failure Fundamentals & RCFA Methodology
Tujuan: Build strong understanding of failure mechanisms and structured RCFA frameworks.
Sesi 1 – Introduction to Root Cause Failure Analysis
- What is RCFA?
- Difference between troubleshooting vs. root cause analysis
- Reactive vs. proactive reliability approach
- The cost of repeated failures
- Overview of industry standards (e.g., API RP 580 for risk-based thinking)
Sesi 2 – Failure Mechanisms in Industrial Equipment
- Mechanical failures (fatigue, overload, misalignment)
- Corrosion mechanisms
- Erosion & wear
- Cavitation in pumps
- Vibration-induced failure
- Thermal stress & creep
- Lubrication-related failures
Sesi 3 – Structured RCFA Methodologies
- 5-Why analysis
- Fishbone (Ishikawa) diagram
- Fault Tree Analysis (FTA)
- Event & Causal Factor Charting
- Barrier-based analysis
- Selecting the appropriate RCFA depth
Workshop 1
- Analyze a pump failure case
- Develop cause-and-effect diagram
- Identify immediate vs. root causes
Hari 2 – Evidence Collection, Data Analysis & Diagnostics
Tujuan: Enable participants to conduct technically sound investigations using data and physical evidence.
Sesi 1 – Failure Investigation Process
- Failure reporting & documentation
- Securing the scene
- Evidence preservation
- Interviewing operators & technicians
- Building a failure timeline
Sesi 2 – Technical Diagnostics & Data Analysis
- Vibration analysis fundamentals
- Oil analysis interpretation
- Thermography basics
- NDT results integration
- Process parameter trend analysis
- Using CMMS history in investigation
Sesi 3 – Human & Systemic Factors
- Human error contribution
- Maintenance strategy gaps
- Design vs. operational mismatch
- Organizational & procedural factors
- Latent vs. active failures
Workshop 2
- Review multi-source data (vibration, temperature, process trend)
- Identify primary and contributing causes
- Distinguish technical vs. systemic failure drivers
Hari 3 – Corrective Actions, Prevention & Reliability Integration
Tujuan: Strengthen participants’ ability to recommend sustainable solutions and prevent recurrence.
Sesi 1 – Developing Corrective & Preventive Actions
- Immediate containment actions
- Long-term corrective solutions
- Design modification considerations
- Maintenance strategy revision
- Monitoring & condition-based improvements
Sesi 2 – Linking RCFA to Reliability Improvement
- Reliability-centered maintenance (RCM) linkage
- Failure Mode & Effects Analysis (FMEA) integration
- KPI tracking (MTBF, MTTR, availability)
- Risk-based prioritization
- Building lessons-learned database
Sesi 3 – Reporting & Communication
- Structuring an RCFA report
- Executive summary for management
- Presenting findings with evidence
- Action tracking & follow-up
- Audit & verification of effectiveness
Final Case Study Workshop
Peserta akan:
- Investigate a complex equipment failure scenario
- Build fault tree or event chart
- Identify root cause(s)
- Recommend corrective & preventive actions
- Mempresentasikan justifikasi teknis
This course is designed for professionals with 2–10 years of experience in maintenance, operations, reliability, or engineering roles, including:
- Maintenance Engineers
- Reliability Engineers
- Mechanical Engineers
- Rotating Equipment Engineers
- Static Equipment Engineers
- Inspection Engineers
- Production / Operations Engineers
- Asset Integrity Engineers
- Supervisors involved in troubleshooting and equipment failure
Prasyarat Pengetahuan
Peserta diharapkan telah memahami:
- Basic mechanical systems (pumps, compressors, valves, piping, heat exchangers, etc.)
- Equipment operation principles
- Preventive and corrective maintenance concepts
- Basic reliability terminology (MTBF, failure rate, etc.)
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