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ME-013

Root Cause Failure Analysis (RCFA) Masterclass

Intensive 5-day course · English, Arabic & European languages

Reliability engineers, maintenance superintendents and plant operations managers examine systematic defect elimination methodologies during this five-day course. Delegates explore Root Cause Failure Analysis (RCFA), Failure Modes and Effects Analysis (FMEA), 5 Whys problem-solving and Fault Tree compilation. Technical sessions supply diagnostic tools to identify physical failure mechanisms, establish permanent operational controls and eliminate recurring machinery breakdowns across operating facilities.

Classroom

Public courses in our cities

  • 19–23 Oct 2026Barcelona£3,080 + VAT
  • 19–23 Oct 2026Jeddah£4,200 + VAT
  • 2–6 Nov 2026Paris£3,600 + VAT
  • 16–20 Nov 2026Muscat£3,080 + VAT
  • 7–11 Dec 2026Manama£3,080 + VAT
  • 21–25 Dec 2026Frankfurt£2,600 + VAT
Show 24 more dates
  • 4–8 Jan 2027Singapore£4,200 + VAT
  • 18–22 Jan 2027Istanbul£2,280 + VAT
  • 1–5 Feb 2027Muscat£3,080 + VAT
  • 15–19 Feb 2027Vienna£3,400 + VAT
  • 1–5 Mar 2027Casablanca£2,280 + VAT
  • 15–19 Mar 2027Barcelona£3,080 + VAT
  • 5–9 Apr 2027Paris£3,600 + VAT
  • 19–23 Apr 2027Manama£3,080 + VAT
  • 3–7 May 2027Amman£3,400 + VAT
  • 17–21 May 2027Frankfurt£2,600 + VAT
  • 7–11 Jun 2027Madrid£3,400 + VAT
  • 21–25 Jun 2027Istanbul£2,280 + VAT
  • 5–9 Jul 2027Berlin£3,400 + VAT
  • 19–23 Jul 2027Vienna£3,400 + VAT
  • 2–6 Aug 2027Milan£3,400 + VAT
  • 16–20 Aug 2027Barcelona£3,080 + VAT
  • 6–10 Sep 2027Paris£3,600 + VAT
  • 20–24 Sep 2027Malaga£3,080 + VAT
  • 4–8 Oct 2027Sarajevo£3,400 + VAT
  • 18–22 Oct 2027Frankfurt£2,600 + VAT
  • 1–5 Nov 2027Dubai£4,200 + VAT
  • 15–19 Nov 2027Istanbul£2,280 + VAT
  • 6–10 Dec 2027Riyadh£4,200 + VAT
  • 20–24 Dec 2027Vienna£3,400 + VAT

Group discount: 2 delegates 20% · 3 delegates 35% · 5 or more delegates 50%

Can't make these dates? We can run this course for your team on dates that suit you. Ask for custom dates · In-house options

Online (live)

With a trainer, on dates to suit your team

This course can be taught live online by a trainer, in English, Arabic or any European language, for one person or a whole team.

£1,850 + VAT

Group discount: 2 delegates 20% · 3 delegates 35% · 5 or more delegates 50%

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Root Cause Failure Analysis (RCFA) Masterclass

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Course overview

Recurring machinery breakdowns erode manufacturing profitability, compromise workforce safety and disrupt production schedules across industrial facilities. Historically, organisations treated failure investigation as an isolated exercise for external technical specialists who produced theoretical reports without engaging frontline craft personnel. Modern asset stewardship reverses this practice by placing structured diagnostic disciplines directly into the hands of site maintenance and operations crews. By conducting systematic evidence collection immediately following an equipment stoppage and mapping component degradation against verified operating records, engineering teams can identify the true physical, human and latent organisational root causes of plant failures. By training multidisciplinary teams to recognise subtle symptoms of equipment distress before physical failure occurs, facilities build collective ownership for asset reliability across every operating shift.

Delegates examine core failure investigation frameworks, combining reactive problem-solving with predictive engineering tools. Course modules explore the step-by-step application of Root Cause Failure Analysis (RCFA), 5 Whys investigation techniques, Barrier Analysis and Fault Tree logic. Practitioners study Failure Modes and Effects Analysis (FMEA) to anticipate equipment vulnerabilities, integrating proactive failure prevention directly into site Reliability Centred Maintenance (RCM) programmes.

Investigating equipment failures generates genuine value only when organisations implement durable physical and procedural controls. The curriculum addresses corrective action governance, maintenance policy refinement and continuous feedback loops between workshops and control rooms. Delegates study methods for embedding continuous improvement into failure reporting routines, ensuring verified engineering solutions protect machinery assets across multi-year operational cycles.

Course objectives

By the end of the course, delegates will be able to:

  1. Evaluate physical equipment functions and identify underlying mechanical failure mechanisms accurately
  2. Investigate equipment failure incidents systematically to identify physical, human and organisational root causes
  3. Formulate and deploy durable engineering and procedural controls to prevent recurrence of identified failure modes
  4. Engage cross-functional maintenance, operations and engineering teams in collective failure investigation workflows
  5. Analyse critical plant equipment systems using structured predictive frameworks to eliminate prospective failure risks

Target competencies

  • Failure investigation
  • Failure control implementation
  • Root cause analysis and 5Y
  • Failure mode identification
  • Reliability engineering

Who should attend

This course suits:

  • Maintenance managers and engineering superintendents
  • Operations managers and plant shift coordinators
  • Reliability engineers and condition monitoring specialists
  • Mechanical and electrical maintenance engineers
  • Workshop supervisors and craft team leaders
  • Maintenance planners and technical specialists

Training methodology

  • Interactive technical presentations and structured lectures introduce failure investigation workflows, logic trees and barrier analysis models.
  • Delegates evaluate actual industrial equipment breakdown case studies, applying 5 Whys analysis, building fault trees and formulating site-specific failure prevention plans.

Course modules

  1. Module 1

    Module 1: Purpose of Failure Investigation, Prevention and Control

    • Aligning failure investigation objectives with corporate business priorities
    • Quantifying the direct impact of equipment failures on profitability and customer satisfaction
    • Operational risk assessment and failure investigation prioritisation
    • Structure and deployment of the Integrated Model of Excellence for Maintenance
  2. Module 2

    Module 2: Understanding Function and Failure Modes

    • Defining equipment operating context, primary functions and secondary functions
    • Evolution of failure mode modelling and common diagnostic mistakes
    • Systematic classification of physical, electrical and operational failure types
  3. Module 3

    Module 3: Principles of Failure Investigation

    • Core principles and workflow of Root Cause Failure Analysis (RCFA)
    • Disciplined data gathering protocols to establish exact event timelines
    • Deepening investigations through Barrier Analysis and Change Identification
    • Determining root causes using iterative 5 Whys questioning techniques
    • Structuring investigation findings using Cause Types and Fault Trees
    • Rigorous data validation and evidence-based analytical methods
  4. Module 4

    Module 4: Principles of Failure Prediction

    • Scope, purpose and mechanics of Failure Modes and Effects Analysis (FMEA)
    • Defining operational criteria for initiating an FMEA study
    • Identifying common methodological pitfalls in FMEA and strategies to avoid them
    • Integrating FMEA outcomes within an enterprise Reliability Centred Maintenance (RCM) programme
  5. Module 5

    Module 5: Implementing Failure Prevention Controls

    • Classification of engineering, procedural and cultural failure controls
    • Decision criteria for selecting the most cost-effective and dependable control
    • Enforcing procedural adherence to ensure long-term control durability
  6. Module 6

    Module 6: Practical implementation methods

    • Structuring the plant organisation to capture institutional learning from failures
    • Identifying key stakeholders required to drive sustainable equipment reliability changes
    • Communication disciplines for sharing failure findings across shifts and departments
    • Embedding continuous improvement mechanisms within the failure learning process

Certificate

Every delegate who completes the course receives an ARUK Training Certificate of Attendance.

Frequently asked questions

How do I register?

Choose a date and city in the schedule and press Register, or send us an enquiry. Our team confirms your place and sends an invoice.

Are fees shown with VAT?

Fees are shown per delegate and exclude VAT, which is added to the invoice where applicable.

Can this course be delivered for our team only?

Yes. Any ARUK course can be delivered in-house at your premises, in a meeting room we book for you, or 1-to-1.

Is this course available online?

Yes. We run it live online with a trainer, on dates that suit your team, for £1,850 + VAT per delegate.

Is there a group discount?

Yes. 20% for 2 delegates, 35% for 3 delegates and 50% for 5 or more delegates on the same course.

Can the course be delivered in Arabic or another language?

Yes. Our courses can be delivered in English, Arabic or any European language, by a trainer who teaches in that language. Mention your preferred language when you register or enquire.

What certificate will I receive?

An ARUK Training Certificate of Attendance.

Related courses

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Root Cause Failure Analysis (RCFA) Masterclass

Key booking terms (read before you register)
  • The full fee is paid in advance, before the course starts.
  • Cancel in writing 30 or more days before the start date (45 for in-house) for a refund. Later than that, the full fee is payable.
  • No refund for non-attendance or partial attendance.
  • Places are for the named delegate only; another person cannot attend instead.
  • Moving to another date or city is only possible if ARUK agrees in writing.
  • Travel, accommodation and visas are your responsibility. A refused visa does not change the cancellation terms.

booking terms and conditions

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Root Cause Failure Analysis (RCFA) Masterclass