Event type: Onsite Training


Root Cause Analysis Advance Workshop

Course Description:

Root Cause Analysis (RCA) Advance is a 5 days’ Workshop designed for an individual participating in RCA investigation as a Team Leader, Facilitator, RCA Specialist, Sponsor or appointing authority.

RCA is a problem-solving methodology for identifying fundamental causes of reliability failures, EHS incidents, and developing effective solutions that prevent failures/incidents from reoccurrence.

Participants of this training will learn the underlying concepts of RCA Management System which includes: Failure/Incident Reporting, Investigation Process and Analysis, Solution Development, Tracking and Implementation. The workshop provides detail understanding of RCA methodology, problems identification, data collections, interview, causes analysis, and develop effective solutions. The participants will also learn the advanced failure and incident analytical skills to identify all root, contributing and latent causes. Participants will conduct the RCA investigation by using the organization’s RCA software.

Benefits & Outcomes:

The RCA Advance Training is a cost-effective solution to provide practical training similar to On Job Training (OJT) in a real Case Study Investigation.
The benefits are:

  • Learn the advance skills to investigate any problem systematically.
  • Enhance the skills & knowledge of the participants & drives them towards practicality & best practices.
  • Improves the quality and effectiveness of the future investigation.
  • Develop the value of professionalism and commitment to the Investigation.
  • Apply the learning of RCA Methodology, Procedures and Roles and Responsibility in real investigation.
  • Improves the capabilities of organization by enhancing the skills & knowledge of their employees.

Workshop Outline Summary:

  • A. Investigation Process Review
  • B. Investigation Preparation
  • C. Kick-off Meeting
  • D. Developing Problem Statement
  • E. Developing Work Plan for conducting investigation
  • F. Brainstorming sessions for Possible Causes
  • G. Field Practice
    • Data Collection, review, and analysis
    • Creating Timeline
    • Building Fault Tree Analysis
    • Identifying (Physical, Human, and Latent) Root Causes
    • Developing Solutions
  • H. Final Reporting
Who Should Attend?

The Participants will learn effectively how to apply the role of a RCA Member, Leader, and Facilitator as required.

5 days

Oil Analysis III Training & ICML Certification

Course Description:
Oil analysis and lubricant performance is your passion, and if you’re ready to be an expert authority for your company and lead a comprehensive, in-house analysis program – Oil Analysis III is the training you need to make this a reality.
Oil Analysis III (OA III) is designed to give managers and reliability professionals the right know-how to develop and implement a strong oil analysis program for their workplace or company. In addition to learning the right metrics for program implementation and evaluation, the OA III student will study the most advanced levels of diagnostics and predictive maintenance to ensure program success. The OA III curriculum is fully aligned with the body of knowledge of the International Council for Machinery Lubrication’s MLA III certification. It also comes with supplemental training materials to ensure knowledge retention.

Learning Objectives

  • Machine Wear
    31 factors contributing to abnormal engine wear, sensitivities of various wear particle technologies and how to determine particle composition by visual inspection.
  • Vibration and Oil Analysis
    Strengths and weaknesses of both vibration and oil analysis on 13 machine problems, combining the two for bearing failure analysis.
  • Fluid properties and Additive Depletion
    Root causes of oxidation and how to measure it, sludge and varnish formation and detection, 14 ways additives are depleted from oil.
  • Contamination
    Count and size particles yourself, six additives that suffer from water contamination, water effects on machines, elemental analysis for dust and dirt contamination.
  • Analysis Technology
    Discover the hidden data from your reports and learn the pros/cons of various measurement technologies.
  • Oil Analysis Program Design
    Select candidate machines, best practices for offsite lab cooperation, optimize interval-based oil changes, successfully gauge oil reaching end of its use, cost-benefit analysis of your program.

Topics Covered
The Level III MLA Body of Knowledge is an outline of concepts that a candidate shall have in order to pass the exam, in accordance with ISO 18436-4, Category III, Annex A.
References from which exam questions were derived can be found in the Domain of Knowledge.

  • I. Lubrication Fundamentals (20%)

    • A. Lubrication Regimes

      • 1. Hydrodynamic
      • 2. Elasto-hydrodynamic
      • 3. Boundary
    • B. Base oils

      • 1. Common mineral oil characteristics

        • a) Paraffinic
        • b) Naphthenic
      • 2. Common synthetic oil characteristics, advantages and disadvantages

        • a) Synthesized hydrocarbons
        • b) Phosphate esters
        • c) Dibasic acid esters
        • d) Polyglycols
    • C. API and other base oil classifications
    • D. Basic lubricant additive functions

      • 1. Antioxidants/oxidation inhibitors
      • 2. Rust inhibitors
      • 3. Corrosion inhibitors
      • 4. Demulsifying agents
      • 5. Viscosity index (VI) improvers
      • 6. Detergents
      • 7. Dispersants
      • 8. Pour-point depressants
      • 9. Foam inhibitors
      • 10. Anti-wear (AW) agents
      • 11. Extreme pressure (EP) agents
  • II. Fundamentals of Machine Wear (15%)

    • A. Common Machine Wear Mechanisms

      • 1. Abrasive wear

        • a) Two-body abrasive wear
        • b) Three-body abrasive wear
      • 2. Adhesive wear
      • 3. Surface fatigue
      • 4. Corrosive wear
      • 5. Fretting wear
      • 6. Erosive wear
      • 7. Electrical wear
      • 8. Cavitation wear

        • a) Gaseous cavitation
        • b) Vaporous cavitation
    • B. Common Machine-specific Wear Modes

      • 1. Gearing
      • 2. Plain bearings
      • 3. Rolling element bearings
      • 4. Hydraulics
  • III. Wear Debris Analysis (21%)

    • A. Analytical ferrography

      • 1. Wear debris analysis techniques

        • a) Light effects
        • b) Magnetism effects
        • c) Heat treatment
        • d) Chemical treatment
        • e) Morphology
        • f) Surface detail
      • 2. Wear particle types, origins and probable causes

        • a) Cutting wear particles
        • b) Spherical particles
        • c) Chunky particles
        • d) Laminar particles
        • e) Red oxide particles
        • f) Black oxide particles
        • g) Corrosion particles
        • h) Non-ferrous particles
        • i) Friction polymers
    • B. Atomic emission elemental spectroscopy

      • 1. Basic determination of wear particle metallurgy from elemental composition
      • 2. Evaluating sequential trends
      • 3. Evaluating lock-step trends
      • 4. Particle size limitations of common atomic emission spectrometers
      • 5. Advanced techniques

        • a) Acid/microwave digestion
        • b) Rotrode filter spectroscopy
      • 6. X-ray fluorescence (XRF) and other advanced elemental spectroscopy methods
  • IV. Analyzing lubricant degradation (25%)

    • A. Oxidative base oil failure

      • 1. Causes of oxidative base oil failure
      • 2. Recognizing at-risk lubricants and applications
      • 3. Strategies for deterring or mitigating base oil oxidation
      • 4. Recognizing the effects of base oil oxidation
      • 5. Strengths, limitations and applicability of tests used to detect and troubleshoot base oil oxidation

        • a) Acid number
        • b) Viscosity
        • c) Fourier Transform Infrared (FTIR) analysis
        • d) Rotating Pressure Vessel Oxidation Test
        • e) Sensory inspection
    • B. Thermal failure of base oil

      • 1. Causes of thermal degradation

        • a) Hot surface degradation
        • b) Adiabatic compression induced degradation
      • 2. Strengths, limitations and applicability of tests used to detect and troubleshoot thermal failure of the base oil

        • a) Acid number
        • b) Viscosity
        • c) Fourier Transform Infrared (FTIR) analysis
        • d) Thermal stability test (ASTM D 2070-91)
        • e) Ultracentrifuge detection of carbon insolubles
        • f) Sensory inspection
    • C. Additive depletion/degradation

      • 1. Assessing risk for common additive depletion/degradation mechanisms

        • a) Neutralization
        • b) Shear down
        • c) Hydrolysis
        • d) Oxidation
        • e) Thermal degradation
        • f) Water washing
        • g) Particle scrubbing
        • h) Surface adsorption
        • i) Rubbing contact
        • j) Condensation settling
        • k) Filtration
        • l) Aggregate adsorption
        • m) Evaporation
        • n) Centrifugation
      • 2. Strengths, limitations and applicability of methods for measuring additive depletion/degradation

        • a) Atomic emission spectroscopy
        • b) Fourier Transform Infrared (FTIR) spectroscopy
        • c) Acid number
        • d) Base number
        • e) Viscosity index (VI)
        • f) Rotating Pressure Vessel Oxidation Test
        • g) Blotter spot test
    • D. Detecting wrong lubricant addition

      • 1. Viscosity
      • 2. Neutralization number (AN/BN)
      • 3. Elemental spectroscopy
      • 4. Fourier Transfer Infrared Analysis
      • 5. Other Tests
  • V. Oil analysis program development and program management (19%)

    • A. Machine-specific test slate selection
    • B. Optimizing frequency of analysis
    • C. Setting alarms and limits

      • 1. Setting goal-based limits for contamination
      • 2. Statistically derived level limits

        • a) Editing data
        • b) Calculating averages
        • c) Calculating standard deviation
        • d) Setting upper and lower limits using the mean and standard deviation
        • e) How changes in system operation or maintenance influence statistically derived inferences
      • 3. Rate of Change Limits

        • a) Calculating rate of change
        • b) Slope-based alarms
        • c) Statistically derived rate of change limits
      • 4. Setting aging limits for fluid properties

        • a) Physical properties
        • b) Chemical properties
        • c) Additive properties
    • D. Managing oil analysis information
    • E. Creating and managing oil analysis procedures
    • F. Scoping oil analysis training for reliability technician, trades people and management
    • G. Performing cost/benefit analysis for oil analysis and contamination control programs

      • 1. Calculating program costs
      • 2. Estimating program benefits
      • 3. Calculating return on investment metrics
      • 4. Generating an effective business proposal
    • H. Quality Assurance

      • 1. Of onsite oil analysis
      • 2. Of offsite oil analysis providers
5 days

Foundations for Effective FMEAs

Failure Mode and Effects Analysis (FMEA) is a systematic method for preventing failure through risk discovery and mitigation of potential failure modes and associated causes. The Foundations for Effective FMEAs (Online) training seminar provides an overview of the concepts and procedures for FMEA and related analyses. The course provides understanding of best in class FMEA processes, including how to utilize lessons learned from past analyses to help reduce product development time and effort.

Prenscia Academy Online courses are delivered in real-time with two instructors available to answer questions and assist via audio or chat. See course calendar for available dates and times.

Learning Objectives

  • Learn the best practice step-by-step process for performing FMEAs
  • Proactively consider potential failures, prioritize issues based on risk and then initiate improvements early in development when modifications tend to have the biggest impact for the lowest cost
  • Examine the key factors that contribute to successful FMEA projects and how to implement an effective FMEA process

Topics included

  • FMEA definition and history
  • Application and benefits
  • FMEA as part of Design for Reliability
  • Types of FMEA and standards used
  • FMEA process
  • FMEA boundary diagrams
  • FMEA P-diagram
  • How to correctly define functions, failures, effects and causes
  • The role of FMEA in Reliability Centered Maintenance (RCM)
  • FMEA actions and tracking
  • Risk analysis and prioritization
  • Design review based on failure mode
  • FMEA and APQP
  • FMEA and validation/DVP&R
  • FMEA facilitation
  • Process FMEA
  • Process control plan
  • FMEA review: key factors
Who should attend
The Foundations for Effective FMEAs course is for managers and engineers that are responsible for oversight or involvement in the creation of Design and Process FMEAs. For anyone that want to create a searchable knowledge base of reliability-related information for their designs that contribute to the development of test plans, control plans, future design efforts and other activities.

Your course requires the use of a computer with a licensed ReliaSoft software installation and an audio device with a microphone. All registrants will receive a temporary ReliaSoft software license.
Instructors will make use of their own webcam. Webcams for attendees is optional.

6 days (3-hour sessions)

RAM for Asset Management

RAM for Asset Management provides an overview of the ways in which reliability engineering concepts and methods can be applied for repairable systems analysis and maintenance planning.

Learning Objectives

  • Understand methodologies that can be applied for repairable systems analysis
  • Identify critical components (or failure modes) and determine the most effective ways to improve system availability
  • Evaluate potential maintenance strategies and calculate optimum PM intervals and/or overhaul times
  • Use simulation to obtain estimated performance metrics that can facilitate decision-making in a variety of areas, such as scheduling planned maintenance, planning for spares, identifying bottlenecks in production throughput and estimating life cycle costs

Topics included

  • Reliability statistical concepts
  • Reliability data types
  • Reliability metrics
  • Weibull and life distribution analysis
  • Event/maintenance log data analysis
  • Reliability data comparisons
  • Repairable system analysis
  • Concept of renewal process
  • Recurrent event data analysis
  • Reliability block diagrams
  • Simulation for maintainability
  • RAM analysis process
  • Life cycle cost estimation
Who should attend
The RAM for Asset Management (Online) course is for maintenance managers, engineers and technicians that need to understand the role of reliability in asset management and have a need to analyze their equipment life data to improve operational availability.

Your course requires the use of a computer with a licensed ReliaSoft software installation and an audio device with a microphone. All registrants will receive a temporary ReliaSoft software license.
Instructors will make use of their own webcam. Webcams for attendees is optional.

7 days (3-hour sessions)

Fundamentals of Reliability

Fundamentals of Reliability provides a solid foundation of the methods, analyses, applications and associated tools in reliability engineering mathematics — from basic data analysis and modeling to advanced methods and concepts. This course will introduce and familiarize attendees with basic statistical concepts such as reliability estimation, data set comparison and basic reliability modeling techniques.

Prenscia Academy Online courses are delivered in real-time with an instructor available to answer questions and assist via audio or chat. See course calendar for available dates and times.

Learning Objectives

  • Become familiar with reliability engineering definitions and principles
  • Develop an understanding of the statistics behind reliability engineering models, including parameter estimation and confidence intervals
  • Understand when and how to use common life distributions, including Weibull, lognormal, normal and exponential
  • Introduce different types of life data analyses, such as Accelerated Life Testing (ALT), Demonstration Testing and System Reliability Analysis

Topics included

  • Reliability statistical concepts
  • Reliability data types
  • Reliability metrics
  • Weibull and life distribution analysis
  • Degradation analysis
  • Warranty analysis
  • Reliability data comparisons
  • Reliability test planning and analysis
  • Stress-strength analysis
  • Introduction to quantitative accelerated life test analysis
  • System reliability analysis with Reliability Block Diagrams (RBDs)
Who should attend
The Fundamentals of Reliability course is for engineers and technicians who need to understand the concepts of reliability engineering and need to develop their skills in reliability life data analysis for product and equipment failures, usage and test results.

Your course requires the use of a computer with a licensed ReliaSoft software installation and an audio device with a microphone. All registrants will receive a temporary ReliaSoft software license.
The instructor will make use of their own webcam. Webcams for attendees is optional.

7 days (3-hour sessions)