Root Cause Analysis Methods & Keys to A Successful Corrective Action
Course End Date:
Root cause failure analysis is a process for identifying the true root cause of a particular failure and using that information to set a course for corrective/preventive action.
From a technical standpoint, it is usually a multidisciplinary problem, typically focused on thetraditional engineering fields such as chemistry, physics, materials, statics, dynamics, fluids, etc.
However, it seems that too often the analysis stops with the technical aspects that are easily understood
in an engineering environment, where the real root cause may exist in the human organization.
In this course, a practical guide to root cause failure analysis will be provided, followed by case studies to
demonstrate both the technical and
organizational nature of a typical root causes failure analysis.
Despite the best efforts to avoid them, failures are still a common occurrence in every industry. Of course, there are the more obvious and well-publicized failures in the automotive, petrochemical, aerospace, and mining industries, just to name a few, but there are also many less catastrophic failures occurring at any point in time. Failures not only represent imperfection in the technical attempt to design and operate complicated systems, but they also represent organizational inability to successfully manage the competing interests of time, quality, and money. Therefore, in the interest of continuous improvement, it is in one’s best interest to learn all one can from these failures, allowing us to avoid
making the same mistake twice.
The root cause failure analysis (RCFA) process begins with the collection phase, followed by the analysis phase, and concludes with the solution phase.
The main objective of this course is to provide participants with a practical guide for performing root cause failure analysis and determining the appropriate corrective/preventive action necessary to avoid the same failure in the future.
Who Should Attend:
Mechanical, maintenance, materials, production, and operations engineers and supervisors and other technical staff working in the field.
• Effective Root Cause Analysis - Identifying the Right Problems.
Discovering the extent of the problem
Determining the depth of the problem
Understanding the reasons for the problem
The necessity for methods in root cause analysis
Emphasizing opportunities for improvement in the system
• Effective Specific Corrective Actions - Solving the Problems Effectively and Efficiently
Validation of corrective actions against root causes and contributors (including use of “units”)
Validation of corrective actions against analytical methods
Using the safety precedence sequence
Determining the proper level of specificity for corrective action statements
Lowering risk with corrective actions
• Effective Monitoring - Making Sure Solutions Work
Deciding what to monitor - process and product
Deciding when to monitor - sooner and later
Deciding how to monitor - observing, sampling and reviewing
Monitoring the program for strengths and opportunities for improvement
• MODEL CORRECTIVE ACTION PROGRAM
Risk Informed Categories
Cause Analysis Matched to Risk Category
Trending Process for Causes
Program Key Considerations
Assigning the investigation
Procedures for conducting investigations
Define post investigation responsibilities
Extent of Condition and Extent of Cause
7 Steps to Developing Better Corrective Actions
Improving Corrective Actions – Distinctions
Monitoring Corrective Actions
What to Measure
When to Measure
How to Measure
Some Suggestions on Monitoring Corrective Actions
Sample Actions to be Taken in an Effectiveness Review Plan
The Measures and Their Placement on the Scale
• ROOT CAUSE ANALYSIS TECHNIQUES REVIEW
Magnitude and Importance of Techniques
Reminders for Using Analytical Techniques
Safety Precedence Sequence
General Fault Tree Analysis
Events & Causal Factors Analysis
Management Oversight & Risk Tree Analysis
• ASSESSING THE ROOT CAUSE TECHNIQUES
Strengths and Weaknesses for Various Root Cause Analysis Methods