Over the course of this three-day event, delegates will develop the abilities needed to put an efficient and scalable RCA problem-solving approach into practise. Delegates will be introduced to an evidence-based, methodical, and organised 10-Step RCA approach that they may use inside their organisation. The training course addresses a modern practical approach to problem solving in maintenance and operations management and is based on some of the most recent research in the field.

This includes RCA principles to clearly define the problem, thorough analysis supported by evidence, creating a specifiic corrective action plan for implementing the solutions and monitoring the effectiveness of those corrective actions. Delegates will be enabled to improve the performance of their operation with practical, techniques that are based on these principles.

By attending this training course, delegates will be able to understand the following:

• Understand RCA terminology, goals, benefits, and stakeholders
• Define problem-solving models used for root cause analysis, including 8D, PDCA, and DMAIC
• Build and manage RCA project teams successfully
• The 10 steps of RCA, including: Cause Identification, Data collection & Analysis, Identify and select Solutions, Implement and Evaluate.
• Practical exercises of the Top 7 analytical tools, including Cause-and-effect, 5Whys, FMEA, 8D and DMAIC
• Assess and work with various data collection plans and methods, as well as data charts and control charts
• Aid production to achieve TAKT and Cycle times
• Implement problem-solving techniques (poka-yoke, multi-voting, etc.) and plan, manage, and verify change
• Case Studies will be provided and worked through with delegates in a separate workbook supplied

MODULE 1: RELEVANT BACKGROUND TO RCA

• Definition and Purpose of Root Cause Analysis

• Core principles that guide effective root cause analysis

• How do we to Stop Problems Happening?

• What Root Cause Analysis will disclose

• Metrics for RCA

MODULE 2: RCA & PROBLEM SOLVING FUNDAMENTALS

• RCA: Problem Solving processes and Quality Management

• Data sources & collection of emperical data

• Introduction to the Top 7 Problem Solving Techniques

MODULE 3: TEAMWORK AND TEAM MANAGEMENT IN RCA

• Teamwork & Team Management groups.

• Team Development Process

• Management & Team Responsibility

MODULE 4: MULTIPLE CAUSES AND TYPES OF ACTION

• Understanding Failure

• Why do failures occur?

• The effect of Failure

• The 5 Whys

MODULE 5: HUMAN ERROR AND INCIDENT ANALYSIS

• The Human Factor & Causes of Human Error

• Solutions for Human Errors

• Incident Analysis

• Improving Corrective Action

• Critical Thinking

MODULE 6:THE RCA PROCESS

• Introduction to the RCA Process

• When to Apply the RCA Process

• Step 1: Define the Problem

• Step 2: Understand the Process

MODULE 7: IDENTIFY POSSIBLE CAUSES

• Step 3: Identify Possible Causes

  • Failure Mode and Effect Cause Analysis (FMECA)

  • Types and Usage of FMECAs

  • FMECA Procedure & Calculations

  • Pareto Analysis – 80/20 Principles

  • Human Reliability Analysis

  • FMECA: Controlling the Hazards

• Using the Flowchart for Causes

• Kepner-Tregoe Problem Solving and Decision Making

• Barrier Analysis: Put barriers in place to prevent incidents

  • Multiple barriers: The Swiss Cheese Model

• Using Brainstorming & the Cause-and-Effect Diagram for Causes

• Practical Case Study

MODULE 8: COLLECT THE DATA

• Step 4: Collect the Data

  • Types of Data

  • Application to Apparent Cause Analyses and Root Cause Analyses

  • Tips for Conducting RCA Investigation Interviews

  • Observation

  • Pictograms

  • Scientific Analysis

  • Additional Tools for High-Frequency Problems

  • Overall Data-collection Plan

MODULE 9: ANALYSE THE DATA

• Step 5: Analyse the Data

  • Tools for Low-Frequency Data

  • Additional Tools for High-Frequency Data

  • Pareto Diagram

  • Identifying Root Causes

MODULE 10: IDENTIFY POSSIBLE SOLUTIONS

• Step 6: Identify Possible Solutions

  • Timing of Recommendations

  • Levels of Recommendations

  • Types of Recommendations

  • Management Responsibilities

  • Assessing Benefit/Cost Ratios

• Step 7: Select Solution(s) to Be Implemented

  • Tools to Assist the Decision-Making Process

  • Selling the Plan

MODULE 11: IMPLEMENT, EVALUATE AND INSTITUTIONALIZE

• Step 8: Implement the Solution(s)

  • Design the Program

  • Develop the Program

  • Starting the Implementation Process

  • Implementation Tips

• Step 9: Evaluate the Effect(s)

  • Monitor the Program’s Performance

  • Improve the Program

• Step 10: Institutionalize the Change

MODULE 12: ORGANIZATIONAL CHANGE

• Resistance to Change

• Organizational Culture

• Project Ownership

• Coaching/Facilitation Skills

• Content versus Process Knowledge

This course runs for 3 days.

Our Road Cause Analysis – Advanced Problem-Solving is available in a variety of formats to best match your needs

In-House training: We bring the training to your location. Available with customized features created to meet your requirements.

Virtual Training: Delivered totally online, our virtual sessions are designed to keep participants engaged through relevant training, activities for practice, and ongoing reinforcement.

Available on request.

Delegates should represent a wide range of personnel in the organisation who are involved in, or dependent on, effective maintenance asset management. These should include:

• Maintenance Artisans, Supervisors, Planners & Managers
• Logistics Supervisors & Managers
• Plant Managers & Engineers
• Project managers and supervisors
• Risk Management Professionals
• Financial Managers
• Quality assurance and control professionals
• Operations & maintenance personnel
• Health, safety, and environmental professionals