Root Cause Analysis

Course Overview

Root cause is an element that brings nonconformance and should be eliminated by the process of improvement. Root Cause Analysis is an aggregate term that depicts variety of methodologies, instruments and systems used to uncover the causes of problems. The root cause is "the evil at the base" that sets the complete cause and effect chain causing the problem (s).

Some of the Root Cause Analysis methodologies are particularly designed for distinguishing the main drivers of the root cause; some are aimed at solving the issue through various techniques, while others offer support for activities of Root Cause Analysis. By becoming familiar with the underlying root cause techniques toolbox, the participants will have the capacity to apply the suitable tool to address particular issue.

Course Objectives

  • Enhancing critical thinking by using the model to intensely examine problems and situations
  • Clarifying the distinction between scientific, innovative and critical thinking
  • Promoting the capacity to support problem solving in circumstances where an expert is being used in solving the issue/problem
  • Expanding the scope of the tool for the analysis of the problem

Course Content

Typical Problems with RCA

  • Why most critical thinking models do not get to the root cause and answer it
  • How can systematic and critical thinking be isolated and integrated
  • Difference between process thinking and the content

Problem Definition

  • How it can be ensured that work done on the problem is the right one
  • Filters and tools for setting priority
  • Developing clear and precise problem statement

Understanding the Process

  • How each issue process is a failure
  • How SIPOC outline can set limits and characterize interrelationships
  • Using flowcharts to penetrate down into the correct part of the process (incorporates practices)

Identifying Possible Causes

  • Five methods for identifying the causes
  • Three preferences for the section or elimination of causes
  • Logic trees as circumstances and end results outline on steroids (incorporates practices)

Data Collection

  • Population versus sampling; options for sampling
  • Checking graphs, tables and sheets for data collection
  • Surveys, interviews and field observation for the precise data

Data Analysis

  • Different tools for discrete data analysis (charts, histograms, modified scatter plot)
  • Tools for softer type data (affinity diagram, relationship digraph)
  • Tools for integrative data analysis

Incidents/Events and Human Error

  • How incident/accident analysis is different
  • Causes and solutions for human error

Facilitation Skills

  • Process facilitation versus content expert
  • Facilitation roles and intervention choices

Rest of the Problem Solving Process

  • Identification and selection of solutions
  • Importance of the issues of the organizational change
  • Models for the understanding of resistance and planning change
  • Implementation and follow-up

Management/Organizational Issues Affecting RCA Projects

  • Cognitive biases affecting root cause analysis
  • Organizational culture impact
  • Structures/roles supporting root cause analysis

Statistical Hypothesis Testing and MS Excel

  • What is being done through T, F, and ANOVA tests
  • How it can be done in MS Excel
  • Using chi-square for data count

Drilling Down with Data

  • Looking at differences as 3+ dimensional space
  • How major components of variation can be sliced
  • Which tools can be used for comparing the data

Course Methodology

The training is going to be highly interactive combination of lectures, group discussions, questionnaires, individual reflections, role plays, simulations and videos.

Target Audience

Quality, safety, risk, reliability managers, process engineers, personnel, occurrence investigators, maintenance managers, reliability professionals, and those from manufacturing and the service sector that are looking at improving their problem solving recurring ability.

Duration

05 Days (08:30–14:30) with appropriate breaks for tea/refreshments and lunch.

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