Course 907: Root Cause Failure Analysis

Root Cause Failure Analysis provides the concepts needed to effectively perform industrial troubleshooting investigations. It describes the methodology to perform root cause failure analysis (RCFA), one of the hottest topics currently in maintenance engineering. It also includes detailed equipment design and troubleshooting guidelines, which are needed to perform RCFA on machinery found in most production facilities.

• Identify common manufacturing errors and deviations
• Understand how to prioritize failure events to analyze, preserve failure data, and order a failure analysis
• Explore systems failure analysis methods and techniques
• Develop and implement effective and efficient root cause failure analysis programs
• How to make RCFA a structured, team based, analytical approach
• and more...

Systems Failure Analysis

• Systems failure analysis Introduction
• What is the problem?
• Defining the problem
• The nature of a problem
• Problems versus symptoms
• Clearly define problem and analysis boundaries
• Product and process nonconformances
• Fault tree analysis introduction
• Design of experiments and systems failure analysis
• Nature Of cause
• Identify, collect, and evaluate relevant data
• Brainstorming and mind mapping
• Human and system reliability
• Analysis pitfalls
• Team assignment
• Select/tailor analysis tools and techniques
• Corrective action
• Conduct interviews and small-group brainstorming sessions
• Identify major contributors to problem occurrence
• Tools & Techniques - Flowcharting
• Develop ranked list and rationale for potential root causes
• Document and review results
• Evaluate each major contributor using a hierarchical structure of root cause categories
• Allocate performance measure losses to root cause categories
• Failure Classification
• Failure modes and effects analysis (FMEA)
• Ordering the analysis team
• Analyze the data: Introducing the logic tree

Introduction to Root Cause Failure Analysis

• General Analysis Techniques
• What is Root Cause Analysis?
• Root Cause Analysis Techniques
• Root cause failure analysis methodology
• Safety-related issues
• Regulatory compliance issues
• Process performance
• System and component considerations
• Change and barrier analysis
• Events and causal factors analysis
• Structured Root Cause Analysis techniques
• Problem identification
• Problem description
• Cause analysis
• Determine Root Cause
• What are the types of causes?
• Causal factor category list
• Determine causes of event
• Solution development
• Practical Problem Solving
• Tools for Root Cause Analysis
• Right tool and method
• Manufacturing Case
• Methods to define and verify root causes
• Tools for developing practical solutions
• Techniques for implementing corrective action
• Assessment and assignment matrix

People and Process

• The role of people and processes
• Role of Management Systems
• Understanding the roles that people typically play in problem solving
• Define new roles
• An introduction to the process
• When, where, why, and how to apply the process effectively

Process for Finding Root Failure Cause

• The Framework
• Methods of data collection
• Reliance on expertise
• Clues for finding root cause
• Testing and verification of causes
• Assignable Cause and Root Cause Analysis
• The Importance of Establishing Codes for Tracking and Trending of Investigations
• Link between system and component
• Formulating and amplifying the problem
• Identifying solutions
• Failure Mode and Effect Analysis (FMEA)
• Writing Troubleshooting guides

Root Cause Failure Analysis (RCFA) Process

• RCFA as a simple, yet disciplined process
• Why did it happen?
• Could it have been avoided?
• How can it be prevented in the future?
• Investigate, rectify and eliminate equipment failure
• Chronic breakdowns
• How to find the latent roots responsible for the breakdown
• Latent roots and the management system weaknesses
• Preserving Failure Data
• Ordering the Analysis
• Analyzing the Data
• Communicating Findings & Recommendations
• Tracking for Success
• Stating the Failure Event
• Stating the Failure Modes
• Hypothesizing
• Verifying Hypotheses
• Determining Underlying Causes (Physical, Human and Latent)

Corrective Action

• Criteria for event description
• Cause and effect analysis corrective action definitions
• Corrective action order of precedence
• Advantages and disadvantages of design modifications, process modifications, procedural modifications, requirements relaxation, screening, and other potential corrective actions
• Evaluating corrective action effectiveness. Inspection caveats
• Corrective action class exercise.
• Corrective Action Requirements.
• ISO 9001 root cause identification and corrective action requirements
• The ISO 9001 Management Review
• Pareto analysis
• Material review, disposition, and corrective action
• Material review, disposition, and corrective action class exercise

Conducting a Cost-Effective Root Cause Failure Analysis

• Root Cause Failure Analysis facilitator
• Root Cause Failure Analysis team leader
• The process expert on conducting a root cause analysis
• The content matter expert pertaining to the event
• Develop a root cause analysis reporting
• Contributory Factor
• Corrective Action
• Person(s) Responsible
• Action Due Date
• Measurement Technique
• Establishing A Value Criterion
• Pick a Cause
• Grab-bag Analysis
• Criteria to compare root cause analysis systems
• Completeness
• Comparability
• Cost-effectiveness
• Growth potential
• Practice Description
• Opportunities for Impact
• Evidence for Effectiveness of the Practice
• Potential for Harm
• Costs and Implementation
• Automating Root-cause Analysis
• Requirements for Analyzing Failure Modes and Their Effects
• Analysis Capabilities in Event Management Systems
• Event Filtering
• Rule-Based Event Analysis
• Model-Based Event Analysis
• Codebook Correlation

Strategies and Solutions for Root Cause Analysis

• Process is the key
• Tools and techniques are essentials
• Technique and tools to develop and implement effective and efficient Root Cause Analysis programs
• Tools and techniques to identify manufacturing errors
• Tools and techniques to trouble shoot
• Addressing the challenges of t Root Cause Analysis investigations
• Tools and techniques for identifying common Root Causes and implemenying corrective actions
• Manufacturing investigations techniques
• Managing corretive action and preventive action

WORKSHOPS

Data Analyzing Workshop

• Analyzing data
• Causal factor charting
• Fault tree analysis
• Using fault tree analysis
• Change analysis
• Determining root causes

Root Cause Failure Analysis Hands-on Workshop

• Determining root causes
• Identifying root causes using a methodology or a process
• Developing conclusions and recommendations
• Conclusions and recommendations based on facts

Case Study: Equipment Design Evaluation

• Pumps
• Fans, Blowers, and Fluidizers
• Conveyors
• Compressors
• Mixers and Agitators
• Dust Collectors
• Process Rolls
• Gearboxes/Reducers
• Steam Traps
• Inverters
• Control Valves
• Seals and Packing
• Equipment troubleshooting techniques
• Others

Case Study: Electrical Troubleshooting

• Understanding Electrical Symbols
• Understanding Ladder Diagrams
• Troubleshooting Tools
• Collecting Information
• Specialized Tests and Equipment
• Troubleshooting hydraulic Systems
• Complete Electrical Diagram
• Complete Hydraulic Diagram