Root Cause Analysis

  
 
 

Calculating Loss

& Prioritizing Failures

  •  Pareto charts are specialized tools that help you focus on the crucial few causes of trouble. Problem areas are then analysed by Root Cause Analysis to identify the source of the problem. This systematic process concentrates your effort on the areas where your effort has the largest impact and where your effort matters most.

 
What is Root Cause Analysis (RCA) ?

  • Root Cause Analysis (RCA) is a structured process that uncovers the physical, human and latent causes of any undesirable event in the workplace.

  • The objective of Root Cause Analysis (RCA) is to identify the “root cause(s)” so that these latent failures may be eliminated or effects mitigated and future occurrences of similar problems or mishaps may be prevented.

  • This technique and its variations have been applied to Military, Aerospace, Medical, Industrial and various other environments with quantifiable success.

 

Our Training Commitment

  • Learn from leaders in the application of reliability methodologies.

  • Utilize a hands-on learning approach through interaction, group exercises and mentoring.

  • Offer attendees the skills and knowledge geared to their appropriate level and role.

  • Ensure participants are empowered with the knowledge to improve equipment performance where it counts: in their own organization.

 

Recommended Participant

  • Maintenance Managers

  • Engineering Managers

  • Plant Managers

  • Operations Managers

  • Trades people

  • Operators

  • Engineers

 

RCA Training Courses

 One-day Basic RCA Training Course

 

1.  What is Root Cause Analysis (RCA)?

  • The RCA Work Process

  • Different RCA Methodologies

 

2.   Proactive versus Reactive RCA

  • Trigger Mechanism for RCA

 

3.  RCA Analysis Approach

  • Preparation

-        Define the System to Analyze

-        Draw process flow block diagram and Describe the function of each block

  • Collect, Summarize and Encode the Data

  • Defining and Calculating Loss

  • Prioritizing Failures

  • Validate Results

  • Project Report

 

4.  Collecting Information for Analysis

  • People

  • Parts

  • Space and Time

  • Data

 

5.  The Analysis Team

 

6.  Analyzing the Data I: Basic Tools

  • 5-Why Analysis

  • Timeline (sequence diagram)

  • The Event and Causal Factor tree, Fish Bone diagram

  Two-day Intermediate RCA Training Course

 

1.  What is Root Cause Analysis (RCA)?

  • The RCA Work Process

  • Different RCA Methodologies

  • Differences between Root Cause Analysis andSix Sigma

  • Root Cause Analysis versus Failure Modes and Effects Analysis (FMEA)

  • Root Cause Analysis and Reliability-centred Maintenance (RCM)

 

2.  Proactive versus Reactive RCA

  • Trigger Mechanism for RCA

 

3.  RCA Analysis Approach

  • Preparation

-        Define the System to Analyze

-        Draw process flow block diagram and Describe the function of each block

  • Collect, Summarize and Encode the Data

  • Defining and Calculating Loss

  • Prioritizing Failures

  • Validate Results

  • Project Report

 

4.  Reliability Key Performance Indicators

  • Mean Time between Failure (MTBF)

  • Maintenance Cost

  • Availability

  • Reliability

  • Key Performance Indicators (KPI)

  

5.  Collecting Information for Analysis

  • People

  • Parts

  • Space and Time

  • Data

 

6.  The Analysis Team

 

7.  Analyzing the Data I: Basic Tools

  • 5-Why Analysis

  • Timeline (sequence diagram)

  • The Event and Causal Factor tree, Fish Bone diagram

 

8.  Analyzing the Data II : Advanced Tools 

  • Fault Tree Analysis (FTA)

  • The Logic Tree

  • Multi-linear Events Sequencing (MES)

  • Failure Mode and Effects Analysis (FMEA)

-        Establish Severity Ratings

-        Establish Probability Ratings

-        Establish Detectability Ratings

-        Complete Basic FMEA Spreadsheet

-        Develop Corrective Action Plan

Which one to use?

 

 Three-day Advanced RCA Training Course

 

1.  What is Root Cause Analysis (RCA)?

  • The RCA Work Process

  • Different RCA Methodologies

  • Differences between Root Cause Analysis andSix Sigma

  • Root Cause Analysis versus Failure Modes and Effects Analysis (FMEA)

  • Root Cause Analysis and Reliability-centred Maintenance (RCM)

 

2.  Creating Successful RCA Environment

  • The Role of Management

  • The Role of a RCA Manager

  • The Role of the RCA Facilitator

  • Expected return on RCA

  • Integrating Root Cause Analysis (RCA) into existing system

 

3.  Proactive versus Reactive RCA

  • Trigger Mechanism for RCA

 

4.  RCA Analysis Approach

  • Preparation

-        Define the System to Analyze

-        Draw process flow block diagram and Describe the function of each block

  • Collect, Summarize and Encode the Data

  • Defining and Calculating Loss

  • Prioritizing Failures

  • Validate Results

  • Project Report

 

5.  Reliability Key Performance Indicators

  • Mean Time between Failure (MTBF)

  • Maintenance Cost

  • Availability

  • Reliability

  • Key Performance Indicators (KPI)

 

6.  Asset Performance Management

  • Automating the Analysis Process

  • Determining Data Needs

  • Workflow to Collect the Data

  • Data Collection System

  • Failure Reporting, Analysis and Corrective Action System (FRACAS)

  • Analyze the Data

 

7.  Collecting Information for Analysis

  • People

  • Parts

  • Space and Time

  • Data

 

8.  The Analysis Team

 

9.  Analyzing the Data I: Basic Tools

  • 5-Why Analysis

  • Timeline (sequence diagram)

  • The Event and Causal Factor tree, Fish Bone diagram

 

10.  Analyzing the Data II : Advanced Tools 

  • Fault Tree Analysis (FTA)

  • The Logic Tree

  • Multi-linear Events Sequencing (MES)

  • Failure Mode and Effects Analysis (FMEA)

-        Establish Severity Ratings

-        Establish Probability Ratings

-        Establish Detectability Ratings

-        Complete Basic FMEA Spreadsheet

-        Develop Corrective Action Plan

Which one to use?

 

11.  Communicating Findings and Recommendations

 

12.  Tracking for Bottom-Line Results
 
 

 

Copyright © Max Honour Consultants Ltd. 2011