PROGRAM'S BACKGROUND

Root Cause Analysis (RCA) is a structured, team based, analytical approach that when used correctly can alleviate recurring problems within an organization. In this program, participants will learn to apply several practical, systematic methods for analyzing incidents and problems to uncover root causes. Understanding of these techniques will be reinforced by exercises as we explore effective ways of gathering data for root cause analysis and how to determine which problems should be analyzed. We will also discuss how to design, develop, and implement a root cause analysis program for your organization.

This program is designed to teach the attendees 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 attendees will feel comfortable going back to the job and attacking chronic plant problems and incidents right away.

PROGRAM'S OBJECTIVES

This Program’s Attendees Will Be More Able To:

›       Develop and implement a sustainable world class maintenance strategy

›       Perform a systematic Root Cause Failure Analysis

›       Develop an improved understanding of numerous maintenance environment variables, and of the relationships between them

›       Understand, audit and optimize your maintenance process

›       Understand the use and application of generic problem solving techniques

›       Cascade the principles and benefits of the program to other employees

›       Develop skill at breaking down operations problems into essential parts

›       Develop skill at quickly modeling the causes of the operations problems

›       Develop skill at analyzing problems and identify controllable root causes

›       Develop skill at targeting corrective actions for maximum systemic impact

›       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 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

PROGRAM'S ATTENDEES

›       Engineering and Technical Professionals and Supervisors from any industry

›       Maintenance Planners and Coordinators

›       Operations and Manufacturing Professionals and Supervisors

›       Foremen and Team leaders

›       Plant Engineers and Maintenance System Professionals

›       Section Engineers and Planners

›       Craft, first line Supervisors, Engineers, Reliability and Maintenance Engineers, and Managers

›       Anyone who may participate in root cause analysis investigations of chronic equipment problems, or serious incidents related to the environment or safety

›       Upper level managers who want to understand how rigorously applying Root Cause Analysis techniques can bolster bottom line results should also attend

PROGRAM'S OUTLINE

INTRODUCTION TO RCA CONCEPTS & OBJECTIVES

›       How to Organize for an RCA

›       Select the Problem to Analyze

›       Define the Problem

›       Identify the Source of the Problem

›       Solution Options Analysis and Selecting the "Best Fit"

›       Putting RCA into practice

›       Finding root causes of unreliability and incidents versus firefighting with chronic problems

›       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 & 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 spreadsheet to determine when each method is appropriate

›       What circumstances trigger the use of RCA

›       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

PROBLEM SOLVING - BASIC PRINCIPLES

›       Problem Identification

›       Terminology of RCFA

›       Decision Logic

›       Three Knowledge Types

›       Maintenance Maturity Indexing

›       Six Level Generic Performance Standard

›       Continuous Improvement

SUSTAINABLE MAINTENANCE PERFORMANCE IMPROVEMENT 1

›       Introduction to Modern Maintenance Practice

›       The SQC Performance Model

›       Reverse Risk Analysis

›       Maintenance /Operations Objectives and Resource Analysis

›       Complexity; Risk; and Variability Models

›       The Maintenance Cost Ratio

›       Solving of Delegate Problems

SUSTAINABLE MAINTENANCE PERFORMANCE IMPROVEMENT 2

›       Cross Referencing Operational Variables

›       Your Maintenance Costs are too High

›       Sigma Sets: The Absolute Decision Standard

›       Data / Knowledge Base

›       Accuracy and Availability of Data / Cost relationship

›       The Four critical stages of Data Maturity

›       Logical Critical Thinking vs. Creative Lateral Divergent Thinking

ROOT CAUSE ANALYSIS

›       Maintenance Strategy Development and Implementation

›       Standard Pitfalls for Maintenance Improvement Initiatives

›       Generic Problem Solving Techniques

›       Logical Problem Solving Techniques

›       Creative Problem Solving Techniques

›       Other Problem Solving Techniques

›       A Systematic Root Cause Failure Analysis Methodology

ACTION PLAN DEVELOPMENT

›       Introduction to TRIZ Methodology

›       Review of Most Suitable Techniques

›       Development of an Instant Approach to Problem Solving

›       Application of Standard Questions 

›       Individual Delegate Requirements

›       Commercial Programs

›       Logistical Requirements for Practical RCFA implementation

ADDITIONAL DETAILS