This 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.

This 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.

Before 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.

In 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.