Root Cause Analysis (RCA)

RCA is an approach for identifying non-conformance underlying causes of why an incident occurred so that the most effective solutions can be identified and implemented.

About this Course

RCA is an approach for identifying non-conformance underlying causes of why an incident occurred so that the most effective solutions can be identified and implemented. It’s typically used when something goes badly, but can also be used when something goes well. Within an organization, problem solving, incident investigation and root cause analysis are all fundamentally connected by three basic questions: What’s the problem? Why did it happen? What will be done to prevent it?

Course Objective

By the end of this course delegates will be able to:

How to define root cause analysis
What are the 5 Whys technique for failure analysis
How to get everyone at the plant engaged in doing 5 Whys
How to find root causes that can benefit corporate goals regarding OEE, injuries, environmental incidents, etc.
Using Logic Trees to uncover the physical, human and latent causes of failures
When it is appropriate to use the Logic Tree
What the primary benefits of the Logic Tree approach
Why gathering and preserving evidence is critical to root cause analysis
How to find the best solutions once you have found the causes
How to insure solutions are implemented and that they are effective
The Causal Factor Mapping technique for failure analysis
When it is appropriate to use Causal Factor Mapping
What the primary benefits of the Causal Factor Mapping approach are
How to establish triggers to know when RCA is appropriate
How to find the chronic failures that are creating the most losses
How to implement an RCA process at your plant
How to identify effective corrective and preventative actions for problems or issues
How to use root cause analysis to reduce risk throughout the organization
How to use root cause analysis to reduce firefighting
How to use an RCA Playbook to determine when each method is appropriate
What circumstances trigger the use of RCA
How driving to the root causes of failures can significantly increase OEE (Overall Equipment Effectiveness), as well as, reduce injuries and environmental incidents

This Course will Highlight on

The primary objective of this course is to recognize the value of conducting proper root cause analysis and documenting failure investigations. Emphasis is placed on the application and practical, hands-on aspects of how to facilitate root cause analysis. Additionally, the course will provide candidates with the principles and techniques involved in identifying failures and deviations, categorizing problems, assigning responsibility and tracking team activities. This course is designed to teach the attendee how to use three of the most popular and useful problem solving techniques available today and Five Whys, Logic Trees, and Causal Factor Mapping. Class lecture will be reinforced with numerous practice opportunities, so the attendee will feel comfortable going back to the job and attacking chronic plant problems and incidents right away.

Training Methodology

Participants on this training course will receive a thorough training on the subjects covered by the course outline, with a combination of theory, practical examples, many exercises and application on issues from their own work environment. Besides training manual, participants will receive additional materials like process cards, work sheets, case descriptions, sample solutions, etc.

Course Outline

Introduction to Root Cause Analysis concepts
Finding root causes of unreliability and incidents versus fire fighting with chronic problems
Use the team approach to identify the right problem and solution
Distinguish root cause from symptom
Use the six problem solving steps
Basic problem solving
Problem solving tools
Compare RCA to FMEA and other reliability improvement techniques
The simple 5 Whys method of failure investigation
Finding how root causes impact business goals
OEE (Overall Equipment Effectiveness)
Injuries
Environmental incidents
Review OEE concepts and how increasing OEE benefits business
Examples of RCA techniques improving OEE
Calculate OEE and revenue improvements from RCA techniques
Causal Factor Mapping for incidents and failures
Using an RCA playbook and spread sheet to determine when each method is appropriate
What circumstances trigger the use of RCA
Flowcharting
Brainstorming
Cause & effect diagrams
Check sheets
Nominal group techniques
How to use FMEA and Pareto to determine which problems to work on
How to implement an RCA process
Selling the benefits of RCA to management
Possible approaches to RCA implementation and how to overcome resistance
Develop an action plan resulting from RCA