Root Cause Analysis (RCA)

Purpose

Root Cause Analysis course will enable participants to understand root cause analysis as a procedure for ascertaining and analyzing the causes of problems in an effort to determine what can be done to solve or prevent them. Consisting of lectures, practice, and role-playing, this course is designed to provide attendees with an in-depth understanding of how to analyze a system to identify the root causes of problems.

Target Audience

Quality, safety, risk, and reliability managers, process engineers, technicians, operations supervisors and personnel, process owners, occurrence investigators, analysts, maintenance directors, reliability professionals, and anyone who wants to improve their ability to solve recurring problems should attend this training.

Course Content

PROBLEM DEFINITION 
A. How to ensure that the right problem is being worked on
B. Tools and filters for priority setting
C. Developing a clear and sufficient problem statement

UNDERSTANDING THE PROCESS 
A. How every problem is a process failure
B. How a SIPOC diagram can set boundaries and define interrelationships
C. Using flowcharts to drill down into the right part of the process

IDENTIFYING POSSIBLE CAUSES 
A. Five ways to identify possible causes
B. Three options for selecting or eliminating causes
C. Logic trees as a cause and effect diagram on steroids (includes practice)

DATA COLLECTION 
A. Population versus sampling; options for sampling
B. Check sheets, graphs, and tables for discrete data collection
C. Surveys, interviews, and field observation for opinions or less precise data

DATA ANALYSIS 
A. Tools for discrete data analysis (run charts, histograms, modified scatter diagram, pivot tables)
B. Tools for softer type data (affinity diagram, relationship digraph)
C. Integrative data analysis tools

CONSULTING CASE STUDY PRACTICE 
A. Participants role play consulting with instructor on a problem
B. Review of key learning points

INCIDENTS/EVENTS AND HUMAN ERROR 
A. How incident/accident analysis differs
B. Causes of and solutions for human error

CASE STUDY PRACTICE 
A. Practice on a project relevant to participants’ organization

BASIC ROOT CAUSE ANALYSIS

Course Content – 4 Hrs Program

• What is Root Cause Analysis
• Define Root Cause Analysis
• Importance of Root Cause Analysis
• Problem-Solving Process Flowchart (8D Roadmap)
• Problems vs. Opportunities
• Preventative Practices
• Problem Detection & Specification
• Steps to Conduct Root Cause Analysis
• The 5 Why’s Technique
• Situation Appraisal
• Known vs. Unknown Cause
• Using Facts, Evidence & Assumptions
• Interim Actions
• Using a Team Approach
• Risk Analysis Tools
• Importance of Language
• Cause-Effect Mapping Methods
• Explain Process of Pareto Analysis
• Steps to Create Fishbone Diagram
• Human Error
• Exercises & Case Studies