Root Cause Failure Analysis & Corrective & Preventive Maintenance Training

Root Cause Failure Analysis, Corrective and Preventive Maintenance

Reliability, Risk Mitigation, and Sustainable Solutions

Claim 3 CPD Points

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Platform:
Online
In-class
Revised and Updated: 23 October 2026
Date Venue Duration
26 - 28 October 2026 Sandton, Gauteng 3 Days
25 - 27 November 2026 Live/Online 3 Days
03 - 05 February 2027 3 Days
28 - 30 April 2027 Sandton, Gauteng 3 Days
07 - 09 July 2027 Sandton, Gauteng 3 Days

Course Introduction

Every organisation establishes vital defences — from robust maintenance and operating procedures to comprehensive training — to mitigate the risk of failure. Despite these efforts, unexpected events can breach those defences, leading to significant undesirable outcomes. Compounding this, chronic, low-level failures, often unnoticed individually, create enormous cumulative costs. Addressing these persistent issues offers a profound opportunity for performance improvement. 

 

Root Cause Analysis (RCA) is a structured process to determine what must be done to prevent the recurrence of undesirable outcomes. Applied correctly, RCA identifies the physical mechanisms of failure, the human actions or inactions involved, and the contributing organisational factors. Uncovering these root causes empowers organisations to generate and implement targeted solutions, strengthening defences and reducing the risk of recurrence. 

 

This Root Cause Failure Analysis, Corrective and Preventive Maintenance course equips participants with the essential knowledge and practical skills required to systematically investigate undesirable outcomes, transforming reactive responses into proactive, data-driven improvements. By examining the underlying causes of equipment failures and operational inefficiencies, the programme empowers individuals and organisations to implement sustainable solutions, enhance reliability, optimise costs, and foster a culture of continuous learning and resilience. 

Course Objectives

The objectives of this Root Cause Failure Analysis, Corrective and Preventive Maintenance course are to: 

  • Understand the Spectrum of Failures: develop a comprehensive understanding of the nature, risks, and various causes of equipment failures, from unanticipated catastrophic events to chronic, high-frequency issues, and their contribution to business success 
  • Master Proactive Risk Mitigation: acquire techniques to proactively manage equipment reliability and risk, focusing on upgrading maintenance and operating procedures, skills, and organisational practices to prevent recurrence 
  • Leverage Failure Data for Insight: learn how to effectively collect, prepare, and analyse failure data, distinguishing between chronic and intermittent issues, and assessing the cost-benefit of conducting a root cause analysis 
  • Apply Systematic RCA Techniques: gain practical proficiency in various Root Cause Analysis methodologies, including Ishikawa (Fishbone) diagrams, the “5 Whys,” and rigorous RCA processes, along with the preparation and organisation required for effective analysis 
  • Develop and Implement Actionable Solutions: learn to apply rigorous RCA to real-world scenarios, develop comprehensive implementation action plans, and understand how to track their execution 
  • Quantify Improvement and Drive Organisational Learning: understand how to calculate the Return on Investment (ROI) of RCA initiatives, ensuring that findings translate into tangible value, and fostering continuous improvement and organisational commitment beyond the technical analysis itself 

Who should attend?

This Root Cause Failure Analysis, Corrective and Preventive Maintenance course is suitable for a wide range of people involved with the maintenance and operation of physical assets. It is important that people who lead or participate in RCA, and those who lead the development of maintenance tactics and a reliability programme for the organisation’s physical assets, attend. Typical delegates include: 

  • Reliability Engineers 
  • Maintenance Planners 
  • Maintenance Supervisors 
  • Technicians, Craftsmen, and Artisans 
  • Operations Supervisors 
Training Methodology

Training Methodology

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.

Training Outline

DAY 1 — The Risk, Nature, and Causes of Equipment Failures
Module 1: The Risk, Nature, and Causes of Equipment Failures
  • The contribution of effective maintenance to business success
  • The risk of unanticipated equipment failure
  • Proactive risk and reliability management
  • Functional failures and failure modes
  • Damage mechanisms, their causes, and their effects

Module 2: Taking Control of Equipment Reliability and Risk
  • Risk mitigation options and techniques
  • Implementing robust programmed maintenance
  • Upgrading maintenance procedures, skills, and practices
  • Upgrading operating procedures, skills, and practices
  • Upgrading organisational procedures, skills, and practices
  • Error-proofing equipment, processes, and procedures
  • International standards relating to RCA

DAY 2 — Failure Reporting, Analysis, and RCA Preparation
Module 3: Failure Reporting and Analysis
  • Failure data requirements
  • Failure data preparation
  • Failure data analysis techniques
  • Distinguishing between chronic and intermittent failure
  • Cost-benefit analysis of conducting a root cause analysis

Module 4: RCA Techniques and Preparation for the Analysis
  • Facilitator selection and appointment
  • Team composition
  • Preparing and organising the analysis, and setting objectives
  • Evidence collection and preservation
  • Recording meetings and proceedings
  • RCA technique selection and training
  • Ishikawa (Fishbone) cause-and-effect diagrams
  • The 5 Whys
  • Fault Tree Analysis
  • Troubleshooting matrices
  • Rigorous RCA

DAY 3 — Practical Application of Rigorous RCA
Module 5: Practical Application of Rigorous RCA
  • Case Study: case study using a generic failure example
  • Case Study: case study using a client-specific failure example
  • Developing an implementation action plan
  • Tracking implementation
  • Calculating the RCA Return on Investment (ROI)

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FAQs – Root Cause Failure Analysis, Corrective and Preventive Maintenance

Find answers to FAQs about root cause failure analysis and corrective and preventive maintenance, including failure investigation, problem-solving techniques and equipment reliability.

What topics are covered in the Root Cause Failure Analysis course?
The course covers equipment failure risks and causes, reliability and risk management, failure reporting and data analysis, root cause analysis preparation and techniques, evidence collection, corrective and preventive actions, implementation planning, and calculating the return on investment (ROI) of root cause analysis initiatives.
Who should attend the Root Cause Failure Analysis and Corrective and Preventive Maintenance course?
The course is suitable for reliability engineers, maintenance planners, maintenance supervisors, technicians, craftsmen, artisans and operations supervisors. It is particularly relevant for people who lead or participate in root cause analysis and those responsible for developing maintenance strategies and reliability programmes for physical assets.
Which root cause analysis techniques are covered?
Participants learn about several root cause analysis techniques, including Ishikawa (Fishbone) cause-and-effect diagrams, the 5 Whys, Fault Tree Analysis, troubleshooting matrices and rigorous root cause analysis. The course also covers selecting appropriate techniques, preparing for investigations and organising analysis teams.
How long is the Root Cause Failure Analysis training course?
The course runs for three days and is available online and in class. In-house training can also be arranged for organisations. Contact Prospen Africa for upcoming dates, pricing and registration details.
Does the course include practical exercises and case studies?
Yes. The training includes group work, workshops, case studies and practical application. Participants work through a generic failure example and a client-specific failure example, develop an implementation action plan, learn how to track its execution and calculate the return on investment of root cause analysis.
How does root cause analysis help prevent recurring equipment failures?
Root cause analysis investigates the physical mechanisms of failure, the human actions or inactions involved, and contributing organisational factors. Identifying these underlying causes helps organisations develop targeted corrective and preventive actions, improve maintenance and operating procedures, strengthen reliability, reduce the risk of recurrence and support continuous improvement.

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