Root Cause Analysis

Designed for:

This is an introductory course designed for craft, first line supervisors, engineers, and managers who may participate in root cause analysis investigations of chronic equipment problems, or serious incidents related to the environment or safety.  Additionally upper level managers should attend who want to understand how rigorously applying Root Cause Analysis techniques can bolster bottom line results.  Lastly, persons who desire to learn how to facilitate Root Cause Analysis investigations should attend, as this course is a prerequisite to the RCA Facilitators class.

You will learn:

• The simple 5 Why method of failure investigation
  
• Causal Factor Mapping for incidents and failures
  
• Using Logic Trees to uncover the physical, human and latent causes of failures
  
• The strengths and shortcomings of each of the above methods
  
• How to use each method by practicing on real problems from your plant
  
• 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
  
• How to use FMEA to determine which problems to work on
  
• How to implement an RCA process within your plant
  
• How to find the most economical solutions to failure events and prevent them from recurring

About the Course:

This course is designed to teach the attendee how to use three of the most popular and useful problem solving techniques available today – 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.

Course Requirements:

There are no prerequisites and everything the attendee will need is provided.  To increase the benefits of the class, each attendee should bring information on 5-6 current plant problems they want to find solutions for.

Introduction to Root Cause Analysis concepts

1. Finding root causes of unreliability and  incidents versus fire fighting with chronic problems
   
2. Compare RCA to FMEA and other reliability improvement techniques

The simple 5 Why method of failure investigation

1. Discuss and demonstrate the 5 Why method
   
2. Practice the 5 Why method
   
3. How to start a 5 Why process at your site
   
4. How to record and audit results
   
5. Strengths and shortcomings of the 5 Why method

Finding root causes impacts business goals

1. OEE (Overall Equipment Effectiveness)
   
2. Injuries
   
3. Environmental incidents

Review OEE concepts and how increasing OEE benefits businesses

1. Examples of RCA techniques improving OEE
   
2. Calculate OEE and revenue improvements from RCA techniques

Using Logic Trees to uncover the physical, human and latent causes of failures

1. Discuss and demonstrate Logic Trees
   
2. Practice the Logic Tree method individually and in groups
   
3. Evidence gathering and preservation techniques
   
4. Strengths and shortcomings of Logic Trees
   
5. Developing proposed solutions to root causes and selecting the best ones
   
6. Recording and auditing results after applying solutions

Causal Factor Mapping for incidents and failures

1. Discuss and demonstrate Causal Factor Mapping
   
2. Practice the Causal Factor Mapping
   
3. Developing possible solutions to CFM root causes and selecting the best ones
   
4. Recording and auditing results after applying solutions
   
5. Strengths and shortcomings of CFM

Using an RCA Playbook and spreadsheet to determine when each method is appropriate. What circumstances trigger the use of RCA?

1. Typical thresholds for
   
   • Production and quality losses
     
   • Serious operating or personnel incidents
     
   • Injuries
     
   • Environmental incidents, etc.
     
2. Customize the spreadsheet for each participant’s site

How to use FMEA AND Pareto to determine which problems to work on

1. Determining the effects of current chronic failures
   
2. Practice developing a chronic failures spreadsheet
   
3. Using Pareto analysis to select chronic failures to address with RCA

How to implement an RCA process

1. Selling the benefits of RCA to management
   
2. Possible approaches to RCA implementation and how to overcome resistance
   
3. Writing out an action plan

REVIEW THE WEEK’S LEARNINGS

• What is the 5 Whys technique for failure analysis?
  
• When is it appropriate to use 5 Whys?
  
• What are the primary benefits of a 5 Whys approach?
  
• How do you get everyone at the plant engaged in doing 5 Whys?
  
• How does finding root causes benefit corporate goals regarding OEE, injuries, environmental incidents, etc?
  
• What is the Logic Tree technique for failure analysis?
  
• When is it appropriate to use the Logic Tree?
  
• What are the primary benefits of the Logic Tree approach?
  
• Why is gathering and preserving evidence so critical to root cause analysis?
  
• How do you find the best solutions once you have found the causes?
  
• How do you insure solutions are implemented and that they are effective?
  
• What is the Causal Factor Mapping technique for failure analysis?
  
• When is it appropriate to use Causal Factor Mapping?
  
• What are the primary benefits of the Causal Factor Mapping approach?
  
• How do you establish triggers to know when RCA is appropriate?
  
• How do you find the chronic failures that are creating the most losses?
  
• How do you implement an RCA process at your plant?

For more information about training,
please email us at langhornejason@alliedreliability.com