Training
Root Cause Analysis Methods: 2-day Workshop
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PROACT Root Cause Analysis (RCA) Methods were developed by Reliability Center Inc. to help companies in defining and solving major complex problems. These methods are very intuitive and take advantage of the synergy of teams and the creativity of the Principal Analysts (leaders) to effectively:
- Classify problems/opportunities according to business impact - OPPORTUNITY ANALYSIS
- Uncover physical, human and systemic root causes - PROACT RCA
- Develop and implement effective solutions - IMPLEMENTATION PLAN
These methods are ideally suited to solve Equipment and Process problems but they can be applied to any problem.
OPPORTUNITY ANALYSIS (OA)
The objective of the Opportunity Analysis is to clearly identify 20% of the repetitive problems that typically represent 80% of the company's losses. These problems are generally considered good candidates for RCA. This methodology is carried out by a team of 2 or 3 people and consists of:
- Defining the area of concern
- Developing a process flow diagram of the defined area
- Identifying main failure modes (actual, not potential)
- Determining business impact fo each failure mode
- Setting priorities for failure mode elimination
PROACT RCA
The objective of PROACT RCA is to uncover the root causes of any repetitive or sporadic problem. Our methodology follows the cause-and-effect trail from the failure back to its root causes; it is carried out by a team of 5-7 people and consists of:
- Selecting the analysis team
- Writing a concise definition of the problem
- Identifying the actual failure modes and their frequencies
- Collecting data (position, people, parts, paper and paradigms - the 5 Ps)
- Analyzing the problem using a fault tree, this includes developing hypotheses and their verification. Most findings in an analysis lead to further data collection, more hypotheses and more verification. This loop is repeated many times until actionable root causes are uncovered
- Suggesting recommendations to eliminate the root causes
The outcome of these analyses generally include: changes in operating procedures, upgrades in PM and PdM programs and/or equipment/process modifications. These improvements provide exceptionally high Returns-On-Investment.
IMPLEMENTATION PLAN
The objective of the Implementation plan is to solve the problem, it is generally carried out by the same team that did the RCA and consists of:
- Developing the recommendations
- Determining their cost and benefit
- Prioritizing implementation of recommendations
- Implementing recommendations
- Tracking results
- Optimizing solutions
WORKSHOP
The workshop is very interactive and covers:
- An introduction to Reliability
- The three methods outlined above
- Several real case studies that highlight the power of the methodologies and motivate the participants to achieve similar results
- Analysis of cases brought to the classroom by the participants, to be dissected and in some cases resolved
More Information
Call: (519) 888-9970
Coordinator: Isabel Meza
Instructor: Tony Rodriguez
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