Equipment Failure Analysis and Prevention Training

Learning Outcomes

• Apply systematic root cause analysis methods to determine equipment failure modes and causes.
• Analyze failure data using tools such as fault tree analysis and failure mode and effects analysis (FMEA).
• Evaluate the effectiveness of existing maintenance strategies and recommend improvements.
• Design preventive and predictive maintenance plans to mitigate common failure mechanisms.
• Implement corrective actions and monitor their impact on equipment reliability.
• Demonstrate the ability to document and report failure analysis findings in accordance with organizational procedures.

Target Audience

This course is designed for maintenance technicians, engineers, reliability specialists, and operations supervisors who are responsible for equipment performance and reliability in manufacturing, mining, or process industries.

Prerequisites

None — open enrollment

Course Outline

Practicals

Overview

Hands-on practicals reinforce failure analysis techniques and prevention strategies. Learners will perform visual inspection, collect and interpret condition monitoring data, apply root cause analysis tools, and develop preventive maintenance plans using real equipment examples.

Practical Activities

• Visual Inspection and Fracture Analysis — Learners examine failed components (shafts, bearings, gears) using visual and low-magnification inspection to identify fracture modes and surface features. (4h)
• Non-Destructive Testing (NDT) Demonstration — Learners perform dye penetrant and magnetic particle inspection on cracked samples to detect surface and near-surface defects. (3h)
• Root Cause Analysis (RCA) Workshop — In teams, learners conduct a root cause analysis on a simulated pump failure using the 5 Whys and fishbone diagram, then present findings. (4h)
• Condition Monitoring Data Interpretation — Learners analyze vibration spectra and oil analysis reports from rotating equipment to identify faults and recommend maintenance actions. (3h)
• Preventive Maintenance Plan Development — Using a case study, learners develop a preventive maintenance plan for a critical piece of equipment, including task lists and frequencies. (2h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total

Component	Out of	Weight
Practical Assignments (rubric-scored)	100%	30%
Daily Average (multiple choice)	100%	20%
Final Test (multi-answer multiple choice)	100%	50%
Final Total	—	100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

How it works

• Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
• Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
• You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
• If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.

Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates	Discount
5	3% off
10	6% off
15	9% off
20	12% off
25	15% off
30	18% off
50	30% off
75	35% off
100	40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.