Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical and Reliability Engineers
• Maintenance and Inspection Engineers
• Design and Quality Engineers
• Project and Plant Engineers
• Technical Supervisors and Maintenance Managers
• Anyone involved in mechanical system troubleshooting or failure investigation

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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

• Understand different types of mechanical failures and their causes
• Apply structured methodologies for root cause failure analysis (RCFA)
• Interpret fracture, wear, fatigue, and corrosion mechanisms
• Select appropriate testing and inspection techniques for failure evaluation
• Recommend corrective and preventive measures based on analysis results
• Enhance reliability and safety through continuous improvement practices

DAY 1

Introduction to Failure Analysis and Engineering Principles

• Welcome and Introduction
• Pre-Test
• Importance of Failure Analysis in Engineering
• Classification of Failures – Mechanical, Thermal, and Chemical
• Engineering Stress, Strain, and Load Relationships
• Failure Criteria and Design Limitations
• Overview of the Failure Analysis Process

DAY 2

Failure Mechanisms and Material Behavior

• Fracture and Crack Propagation
• Fatigue Failures and Cyclic Loading
• Creep and Thermal Degradation
• Corrosion and Erosion Mechanisms
• Wear and Surface Damage Analysis
• Material Selection and Metallurgical Factors Affecting Failure

DAY 3

Failure Analysis Techniques and Tools

• Visual Examination and Documentation
• Non-Destructive Testing (NDT) Methods
• Destructive Testing and Metallographic Analysis
• Fractography and Microscopy Techniques
• Chemical Analysis and Material Characterization
• Data Collection and Evidence Preservation Procedures

DAY 4

Root Cause Analysis and Problem-Solving Methodologies

• Root Cause Failure Analysis (RCFA) Framework
• 5-Why, Fishbone (Ishikawa), and Fault Tree Analysis
• Event and Causal Factor Charting
• Statistical and Reliability-Based Approaches
• Reporting and Communication of Findings
• Developing Corrective and Preventive Action Plans

DAY 5

Case Studies, Reliability Improvement and Wrap-up

• Real-World Failure Case Studies in Mechanical Systems
• Lessons Learned from Design and Operational Failures
• Reliability and Maintenance Strategies for Prevention
• Continuous Improvement and Best Practices
• Post-Test
• Certificate Ceremony