Start Date: 10 Oct, 2027
End Date: 14 Oct, 2027
Duration: 5 Days
Overview:
This advanced course offers a practical refresher on rotating and reciprocating machinery, focusing on common operational issues and diagnostic challenges. It builds a strong foundation for engineers and technologists transitioning into machinery diagnostics and reliability roles. Through real industrial case studies, participants will learn how to detect, locate, and analyze mechanical faults using proven methodologies.
Course Objectives:
- Employ a systematic approach to investigating mechanical failure
- Plan testing, measurement and analysis to help discover the causes of a failure
- Design and evaluate solutions based on your understanding of the causes of failure Design and evaluate measures to prevent the failure reoccurring
- Recognize a good explanation from a poor; understand how evidence supports explanations and when it doesn’t, and be able to evaluate explanations qualitatively and quantitatively using a variety of simple techniques
Course Content:
1. Machine Failure
Why machines fail
Types and causes of failure
Plant-level impact and cascading failures
Failure modes
Chronic vs. sporadic failures
2. Machinery Troubleshooting
Diagnostic approaches for:
Pumps
Compressors
Turbines
Bearings
Couplings
Lubrication systems
3. Alignment and Balance
Importance and benefits of correct alignment
Types and consequences of misalignment
Unbalance types and causes
Key balancing considerations
4. Failure Analysis Tools
Failure Modes and Effects Analysis (FMEA)
FMECA and risk-based maintenance
Technical integrity audits
FMEA worksheets and limitations
Hands-on case study
5. Methodologies & Strategies
Brainstorming techniques
Flowcharts, histograms, Pareto & fishbone diagrams
Cause and effect analysis
Fault tree analysis
Actionable recommendations
6. Common Issues in Failure Analysis
Turning problems into improvement opportunities
Keys to improving plant profitability
“5 Whys” and “7 Points” for effective RCA
Staying updated with evolving practices
7. Planning & Scheduling Techniques
Importance of maintenance planning
Planning levels and processes
Weekly scheduling, procedures, and checklists
Look-ahead planning and priority setting
8. Maintenance Hierarchy
Goals of maintenance
Reactive, preventive, and predictive strategies
TPM, RCM, and OEE explained
Maintenance management principles
9. Maintenance Performance Evaluation
Evaluation criteria:
Environment, operations, materials, and support
Planning, cost control, and mobile services
Organizational effectiveness and KPIs
10. Machinery Reliability
Reliability techniques and tools
Dependability and life-cycle thinking
Human factors in reliability
Maintainability and system performance
Targeted Audience:
This course is ideal for:
Mechanical engineers
Facility and technical managers
Maintenance and reliability professionals
Project and discipline leads
Anyone tasked with resolving machinery failures or leading teams of differing technical opinions
