Root Cause Analysis of Systems Failure Comprehensive Training

Commitment 5 Days, 7-8 hours a day.
Language English
User Ratings Average User Rating 4.8 See what learners said
Delivery Options Instructor-Led Onsite, Online, and Classroom Live


This four- to five-day Root Cause Analysis of Systems Failure Comprehensive Training course brings together important concepts from engineering, quality assurance, problem-solving, procurement, and other disciplines to identify and eliminate the root causes of failures occurring in complex systems, subsystems, and components.

We will show you how to utilize fault tree analysis for identifying potential failure causes.  We will also arm you with procedures and technologies for working through various types of systems failure.  We will learn how hardware analysis, statistical analysis, design of experiments, technical data package evaluation, and other pertinent tools and techniques can be brought together to define the root causes of a failure and to develop a plan of corrective actions.  The Root Cause Analysis of Systems Failure Comprehensive Training course will utilize real-life case studies to help you apply this toolkit effectively to your job.  At the end of the course, you will have learned how to identify dominant failure modes through quantity and cost-based Pareto analysis, identify the root causes of systems failures, select and implement effective corrective actions, and work as an inter-organizational, multi-disciplinary failure analysis team.

  • 5 days of Root Cause Analysis of Systems Failure Comprehensive Training with an expert instructor
  • Root Cause Analysis of Systems Failure Comprehensive Electronic Course Guide
  • Certificate of Completion
  • 100% Satisfaction Guarantee



Upon completing this Root Cause Analysis of Systems Failure Comprehensive Training course, learners will be able to meet these objectives:

  • Work together in an effective multi-disciplinary team environment to resolve complex system failures.
  • Objectively identify all potential failure causes using fault tree analysis and other technologies.
  • Objectively evaluate the likelihood of each potential failure cause.
  • Identify the most likely failure causes.
  • Proactively eliminate additional potential failure causes before they occur.
  • We can adapt this Root Cause Analysis of Systems Failure Comprehensive course to your group’s background and work requirements at little to no added cost.
  • If you are familiar with some aspects of this Root Cause Analysis of Systems Failure Comprehensive course, we can omit or shorten their discussion.
  • We can adjust the emphasis placed on the various topics or build the Root Cause Analysis of Systems Failure Comprehensive course around the mix of technologies of interest to you (including technologies other than those included in this outline).
  • If your background is nontechnical, we can exclude the more technical topics, include the topics that may be of special interest to you (e.g., as a manager or policy-maker), and present the Root Cause Analysis of Systems Failure Comprehensive Training course in a manner understandable to lay audiences.

The target audience for this Root Cause Analysis of Systems Failure Comprehensive course:

  • This course is aimed at manufacturing engineers, quality engineers, project engineers, design engineers, MRB engineers, procurement specialists, manufacturing managers, program managers, and others responsible for preventing or determining the cause of a systems failure.

The knowledge and skills that a learner must have before attending this Root Cause Analysis of Systems Failure Comprehensive course are:

  • While there are no formal prerequisites, the course does assume a process, industrial, manufacturing, or engineering background.


Day 1: Introduction to Systems Failure Analysis
  • The need for efficient systems failure analysis
  • Systems failure analysis philosophy
  • The four-step problem-solving approach
  • Systems and component failure analyses
  • The inherent value of failed hardware
  • Failure analysis definitions and basic failure analysis concepts
  • Continuous improvement concepts and the failure of the system analysis contribution
  • A framework for systems failure analysis
  • Quality measurement and reporting concepts
  • Non-conformance database approaches
  • Pareto analysis
  • Integrating the cost of quality of the program
  • Understanding systems interactions and how systems operate
  • The value of a priori failure cause identification
  • Case study
Day 2: Fault Tree Analysis
  • Fault tree analysis history, applications, and capabilities
  • Defining the problem and developing fault tree analysis of top undesired events
  • Relationships between logic operators and events
  • Fault tree gate usage and interpretation
  • Using inhibit functions to model probability distributions
  • Navigating from the failure site
  • Quantifying top undesired events
  • Failure rate sources
  • Using fault trees to identify redundancy-defeating failure modes
  • Using Failure Mode Assessment and Assignment (FMA&A) matrices for managing the systems failure analysis effort
  • “What’s Different” analysis
  • Use of test and inspection data, material certifications, and statistical process control data
  • Use of flow charts for product performance and process evaluations
  • Interviewing techniques for use with assembly, test, and inspection personnel. Failed hardware analysis
  • Case study
Day 3: Design of Experiments and Systems Failure Analysis
Basic experimental design concepts
  • Deterministic versus statistical thinking
  • Hypothesis testing
  • The normal distribution and other basic statistical concepts
  • Analysis of variance
  • Z-tests, t-tests, and f-tests
  • Identifying potentially critical design and process parameters
  • Identifying test objectives
  • Test readiness reviews
  • Inducing failures to confirm causes
  • Introduction to Taguchi philosophies and Taguchi design of experiment technologies
  • Designing a Taguchi experiment
  • Selecting test parameters
  • Two and three-level orthogonal arrays
  • Selecting output parameters and data collection approaches
  • Strategies for minimizing test risk
  • Signal-to-noise ratios
  • Defining test specimen configurations
  • ANOVA applied to Taguchi experiments
  • Typical test strategies
  • Multiple level experiments
  • Case study
Day 4: Specialty Analyses, Corrective Action, and Course Wrap Up
  • Evaluating failed hardware compliance
  • Assessing technical data package adequacy
  • Common technical data package shortfalls
  • Tolerance analysis
  • Quality Assurance compliance assessment tools
  • Optical microscopy, SEM, FTIR, EDAX, X-ray, N-ray, SIMS, and Auger analysis
  • Monte Carlo simulations
  • Evaluating leaks
  • Basic metallurgical and electronic component evaluations.
  • Customer/supplier interface issues
  • Commercial failure analysis laboratories
  • The advantages of eliminating repair, rework and using as-is dispositions
  • Corrective action order of precedence
  • Design modifications, process modifications, requirements relaxation, screening, and other corrective actions
  • Use of statistical process control as a corrective action
  • Using the FMA&A matrix for corrective action identification and tracking
Day 5 (Workshop Day): Participants will work together to analyze a failure specific to your organization. The workshop day can be scheduled a few weeks after the first four days of this course to allow time for “homework”.
  • Course Wrap-up
    • A suggested failure analysis procedure
    • Creating a product-oriented Lessons Learned document
    • Recap, Q/A, and evaluations
Root Cause Analysis of Systems Failure Comprehensive TrainingRoot Cause Analysis of Systems Failure Comprehensive Training Course Wrap-Up