Root Cause Failure Analysis
Our Root Cause Failure Analysis service helps you uncover the true reasons behind equipment, component, or system failures. Using a structured, evidence-based approach, we go beyond the symptoms to identify the underlying causes, whether mechanical, material, design, or operational. By combining advanced diagnostic tools with decades of engineering expertise, we deliver actionable insights that not only resolve current issues but also prevent future breakdowns. The outcome is increased reliability, reduced downtime, and long-term cost savings for your operations.
RCFA Methodology
Step 1: Collecting Data
We will listen to you and ask many questions to find out under which circumstances equipment breaks down. Fixing the problem is only half the story, the real value comes from understanding why it failed in the first place. That's why good communication with responsible operators and maintenance personnel is crucial for the entire process. We will dig deep to identify the true reasons behind failures. This includes gathering of information about failure history, design, materials, operating and environmental conditions, methods and current maintenance strategies or data from condition monitoring for the equipment involved.
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Step 2: Analysis
Applying data-driven diagnostics by using the Ishikawa diagram to identify not just the symptoms but the fundamental causes of failure.
Common influencing factors include:
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Methods (procedures, operating practices)
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Machines (equipment, tools, hardware)
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Materials (raw materials, consumables, lubricants)
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Manpower (skills, training, human factors)
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Measurement (calibration, data quality, inspection methods)
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Environment (temperature, humidity, contamination, vibration)
This structured approach ensures accurate findings and supports evidence-based decision-making.
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Step 3: Solution
Once the cause of failure is identified, we suggest corrective actions. This may involve redesigning components, adjusting material specifications, refining maintenance practices, modifying operating procedures, improving lubrication schedules and/or methods, switching to another lubricant, update training or refining condition monitoring methods.
We then support you through implementation, ensuring changes are practical, cost-effective, and aligned with your business goals. The result is improved asset reliability, optimized maintenance strategies, and reduced operational risk. Finally, we validate the effectiveness of these measures through testing, monitoring, and performance reviews, so you can be confident the problem is solved at its source and won’t return.
