Practical Engineering Failure Investigation & Root Cause Analysis
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About This Course
Engineering failures are rarely explained by a single technical defect or human error. Effective investigation requires systematic examination of evidence, identification of contributing factors, and development of corrective actions that prevent recurrence.
Practical Engineering Failure Investigation & Root Cause Analysis is a self-paced professional development course designed to strengthen practical investigation and engineering problem-solving skills.
Through realistic, fictional engineering scenarios, learners will practise:
- Distinguishing failure symptoms, mechanisms, contributing factors and underlying system weaknesses.
- Applying Root Cause Analysis techniques, including 5 Whys, Fishbone diagrams, causal mapping and barrier analysis.
- Interpreting technical evidence and simple engineering calculations.
- Challenging assumptions and evaluating competing explanations.
- Identifying effective corrective and preventive actions.
- Developing action plans with measurable verification criteria.
Practical Case Studies
Case Study 1 — Recurring Packaging-Line Failures
Investigate repeated production stoppages following a production-speed increase. Examine capacity limitations, mechanical failures, control-system evidence and management decisions.
Case Study 2 — Warehouse Incident Investigation
Analyse a forklift collision involving utility piping. Examine physical clearance, operational conditions, safety barriers and organisational factors.
Who Should Enrol?
Engineering undergraduate and postgraduate students, graduate engineers, maintenance and reliability engineers, quality and safety professionals, and industry practitioners.
Course format: Self-paced online learning with guided exercises, case studies and knowledge assessments.
Estimated learning time: 5–7 hours.
Prerequisites: Basic engineering awareness. No specialist software required.
Assessment: Six quizzes, including a final 15-question assessment requiring a minimum score of 80%.
Certificate: A 3MEC Academy Certificate of Completion may be issued manually after verification of all required learning activities and successful completion of the final assessment.
Curriculum
- 7 Sections
- 23 Lessons
- Lifetime
- Module 1 — Introduction to Engineering Failure Investigation4 ItemsThis module introduces the principles of engineering failure investigation and Root Cause Analysis (RCA). You will learn how to distinguish observed failures from assumed causes, recognise the importance of evidence, and understand the investigation process used throughout this course.
- Module 2A — Root Cause Analysis Tools and Techniques6 ItemsThis module introduces practical Root Cause Analysis (RCA) methods used in engineering investigations, including 5 Whys, Fishbone diagrams, causal mapping and barrier analysis. Learners will examine the strengths and limitations of each technique and practise selecting appropriate methods for investigating engineering failures. Particular emphasis is placed on avoiding unsupported assumptions, recognising multiple causal pathways and linking analysis to reliable evidence.
- 2.1Lesson 2.1 — The 5 Whys Method: Applications and Limitations12 Minutes
- 2.2Lesson 2.2 — Fishbone Diagrams: Identifying Contributing Factors12 Minutes
- 2.3Lesson 2.3 — Causal Mapping: Understanding Multiple Failure Pathways15 Minutes
- 2.4Lesson 2.4 — Barrier Analysis: Understanding Failed Controls15 Minutes
- 2.5Lesson 2.5 — The Engineering Investigation Process20 Minutes
- 2.6Quiz 2.6 — Root Cause Analysis Methods15 Minutes10 Questions
- Module 2B: Guided Worked Example: Root Cause Analysis in Everyday Life1 ItemBefore beginning the industrial case studies, watch this complete worked example to see how an investigation progresses from an initial problem to evidence-based causes, corrective actions and effectiveness verification.
- Module 3 — The Reject Spike: An Interactive Engineering Investigation2 ItemsIn this module, you will investigate a fictional production-quality problem involving a sudden increase in rejected products. Acting as an engineering investigation team, you will examine initial operating data, develop competing hypotheses and receive additional evidence in stages. You will use Root Cause Analysis methods to revise your conclusions, distinguish genuine product defects from possible measurement problems and propose evidence-supported corrective actions. The exercise emphasises critical thinking, uncertainty and the importance of investigating before assigning blame.
- Module 4 — Case Study 1: Packaging-Line Failure Investigation7 ItemsInvestigate recurring stoppages in an automated packaging line through a staged engineering case study. Analyse production capacity, motor overload trips, sensor and control-system evidence, and organisational contributors. Develop and justify corrective actions under budget constraints, assess production targets, and verify engineering recommendations.
- 5.14.1 — The Initial Incident and Competing Hypotheses15 Minutes
- 5.24.2 — Evidence Release 1: Capacity and Downtime20 Minutes
- 5.34.3 — Evidence Release 2: Fault and Control-System Records25 Minutes
- 5.44.4 — Evidence Release 3: Physical Inspection and Organisational Evidence20 Minutes
- 5.54.5 — Corrective Actions Under Budget Constraints15 Minutes
- 5.64.6 — Final Engineering Recommendation and Technical Debrief15 Minutes
- 5.74.7 — Quiz Packaging-Line Failure Investigation: Knowledge Assessment15 Minutes10 Questions
- Module 5 — Case Study 2: Warehouse Incident Investigation7 Items
- 6.15.1 — The Warehouse Incident: Initial Investigation10 Minutes
- 6.25.2 — Evidence Release 1: Event Timeline and Witness Accounts15 Minutes
- 6.35.3 — Evidence Release 2: Measurements and Physical Conditions10 Minutes
- 6.45.4 — Evidence Release 3: Safety Barriers and Organisational Evidence15 Minutes
- 6.55.5 — Corrective Actions Under Competing Constraints15 Minutes
- 6.65.6 — Final Incident Assessment and Technical Debrief10 Minutes
- 6.7Quiz 5.7 — Warehouse Incident Investigation15 Minutes10 Questions
- Module 6 — Integrated RCA Assessment and Course Completion2 Items
Instructor
Dr M. Amir Siddiq is a Reader in Solid Mechanics & Materials at the University of Aberdeen, UK, and a Chartered Engineer (CEng), Fellow of IMechE and IOM3, and Senior Fellow of Advance HE (SFHEA).
He has over 20 years of experience spanning engineering industry, academic research and higher education. His expertise includes engineering failure analysis, structural integrity, computational mechanics, advanced materials and engineering simulation.
Through 3MEC Academy, he combines academic knowledge, industrial experience and realistic engineering case studies to help engineers, graduates and students develop practical problem-solving, Root Cause Analysis and evidence-based decision-making skills.
