Level II - Failure Analysis Methods

Purpose and Scope

This course introduces the experienced maintenance and reliability professional who has completed the Level I Failure Mode Identification to additional analytical tools used to determine why a machine failed and how to eliminte physical roots of failures.  Techniques used to quantify the physical mechanisms causing shafts, bolts, bearings, gears, belts, couplings, and other machinery parts to fail are presented in this course.  Advanced inspection and analysis techniques are practiced by the participants.

Case studies, using a variety of failed parts, will be analyzed by participants to determine functional failures and physical failue mode(s).  Participants will learn how to distinguish between functional failures and physical failure modes. The vital elements of documentation will be demonstrated and practiced to show the importance of consistent language.  Various failure analysis and their important features will be introduced.  Using information from actual failures, particpants will learn how to select a method that will produce the best results given available resources.  Participants spend approximately 50% of the class time using a variety of failed parts to learn analytical, investigative and documentation skills to further develop proficiency.


After completing this course, participants will be able to: identify functional failures and examine failed components to determine the physical and human roots. They will be able to use an appropriate analytical method to produce effective results that will prevent repeated failures.   They will be able to accurately identify, describe and use where appropriate:
• Functional failures
• Physical failure modes
• Fault tree analysis
• Change analysis
• Five why
• Failure reporting and corrective action system
• Kepner Trego analysis
• Failure codes and descriptors
Upon returning to work, participants will be expected to immediately utilize the identification and analysis skills taught in the class to target the latent, human and physical roots of equipment failures and describe countermeasures needed to prevent the same or similar failures from occurring.
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