Root Cause Analysis Training For Engineers

Root Cause Analysis Training for Engineers

Root Cause Analysis Training for Engineers Course Description

Root cause analysis training for engineers provides the methodology, theory, and principals of the root cause analysis procedures. Root cause analysis (RCA) techniques, which is basically a problem solving method, helps you identify the root causes of failures and problems with the goal of determining ways to solve or inhibit them. The RCA is known as an effective quality approach.

Root cause analysis training course will also help you develop an appropriate corrective action plan right after the causes of a failure is detected. The root cause analysis methods can be applied in both simple and complex processes.

Since this root cause analysis hands-on seminar is designed for engineers, the course considers the situations involving incidents, failure reports, performance problems in industrial plants, and so on. The training can be used in mechanical, chemical, electrical, and control engineering fields. The goal is to develop a logical engineering thought process instead of using some specific software.

Added Value of Root Cause Analysis Training

• Teaches you the practical methods associated with the RCA
• Determines where/when RCA is the most effective
• Encourage the RCA engineers to deliver tangible solutions to intractable problems
• Teach the RCA methods to the junior engineers
• It provides long term and permanent improvement in the organization
• It creates an analyzing mind-set that will help you in analyzing root causes of problems and incidents in other aspects of your life

Learn About:

• The logic and concept of root cause analysis
• Various techniques of brainstorming potential causes
• Different methods of collecting data
• Various tools for identifying and eliminating the causes of a problem
• Practical ways to implement solutions
• The nature, diversity, and construction of engineering problems
• Other problem solving methods
• Various categories of technical problems in the field of engineering
• Writing technical reports that include the results of root cause analysis
• Engineering cause and effect relationships
• Poor engineering characteristics
• 5 “whys”
• Difference between the RCA and problem solving
• Technical consulting for RCA
• 8D
• Gemba
• Plan, Do, Check, Act (PDCA)
• Cause and effect diagrams
• Cause and escape point
• Fault tree analysis
• Pareto analysis
• Mistake proofing (Poka Yoke)

TONEX Root Cause Analysis Training for Engineers Methodology

TONEX RCA training course is in the form of an interactive workshop. The seminar is composed of in-class activities including hands on practices, case studies, and workshops. During the RCA training course, participants can bring in their own sample projects and problem statements and through our coaching, conduct a root cause analysis procedure for them.

Audience

Root cause analysis training for engineers is a 2-day course designed for:

• Quality, safety, risk, and reliability engineers
• Process engineers
• Operations engineers
• Project engineers
• LEAN engineers
• 6 Sigma engineers
• Designer engineers
• IT engineers

Training Objectives

Upon the completion of root cause analysis training for engineers, attendees are able to:

• Improve the effectiveness of their problem solving skills through developing models for analyzing the complex engineering problems
• State the objectives of root cause analysis
• Describe the problem solving processes
• Apply appropriate and effective problem cause data collection methods based on the nature of each problem
• Successfully and effectively apply the root cause analysis tools
• Derive efficient and effective corrective action plans
• Understand when analytical thinking methods and when creative thinking techniques should be applied
• Provide sufficient problem solving support in the engineering situations where they are not expert of
• Use more variety of tools for analysis of engineering problems
• Discuss the bases of root cause analysis
• Search through the possible root causes of a failure that is beyond a quick fix
• Identify the event chains leading to a failure
• Recognize required actions to avoid reoccurrence of a certain problem of failure
• Create a fault tree for an accident
• Seek similar and relevant evidence in an engineering failure investigation
• Trace the causes of equipment failure or industrial incidents
• Identify high-risk situations and perform preventive action

Course Outline

Overview of Root Cause Analysis (RCA)

• Definition of RCA
• History
• Purpose of RCA
• Applications of RCA in the engineering world
• Gathering evidence and data
• Why most problem solving methods cannot identify the real root of the cause, and a solution
• Analytical vs creative thinking
• Content vs process thinking

Practical Problem Solving

• Engineering problem definition
• How to spot the right problem?
• Identifying the problem
  • Defect Creation
  • Physics of Failure
  • Human Factors
  • Life Cycle Gaps
  • Hidden Failures
• Production plant and equipment failure
  • What reliability engineering tells us about failure

• Techniques to prioritize
• Developing a clear and descriptive problem statement is crucial
• Strategies to solve problems
• Causes and their levels
• Find the roots
• Be a proactive problem solver
• Tools for Problem Understanding
  • Problem Understanding
  • The Purpose and Applications of Flowcharts
  • Using Flowcharts
  • Checklists
  • Using Critical Incidents
  • Using Performance Matrices

Understand the Process

• How every problem can lead to a process failure
• Use SIPOC to define boundaries and interrelationships
• How flow-charting can get you to the right phase of the process

Figure Out All Potential Causes

• Five options to determine all hidden causes
• Three approaches to choose or remove causes
• Fault Tree Analysis (FTA) approach
• Fishbone diagrams (aka. cause-and-effect diagrams)
• Tools for Problem Cause Brainstorming
  • Brainstorming to Find the Causes
  • Brainstorming Objectives and Applications
  • Templates for Brainstorming

Collecting and Analyzing Data

• How to gather relevant information
• Utilizing historical and operational records
• How to do samplings step-by-step
• Relationship between population and sampling
• Use check sheets, graphs, and tables
• Advantages of surveys, interviews, and field observation for opinions
• How to generate and use data collection checklist
• Data analysis process
• Tools for evaluating the gathered data
  • Run charts
  • Histograms
  • Pareto diagram
  • Modified scatter diagram
  • Pivot tables
• How to evaluate the soft data
  • Affinity diagrams
  • Relationship diagrams
• Integrative data analysis tools

Accidents Analysis and Role of Human Error

• Available analysis methods
• What are the causes and solutions for human errors?

How to Eliminate the Identified Root Cause?

• DeBono’s Six Hats

Facilitation Skills

• Difference between process facilitation and content expert
• Facilitation and interference choices

How to Dig into Data?

• Variables in a 3D space
• Separating the major elements
• What are the methods to compare the data

Statistical Techniques

• Statistical tests
  • t, F, and ANOVA tests
• How Excel can help you with these tests
• Using Chi-square to count data

Management Behaviors Affecting RCA Studies

• RCA affected by the cognitive biases
• Organizational culture effects
• Supportive roles

Putting the Selected Solution in Action

• Planning how you want to implement the solution
• Creating a detailed action plan
• Tree diagrams application
• How to prepare to accept the change and implement it?
• How to execute force-field assessment?

TONEX Hands-On Workshop Sample

• Practice on a project relevant to your organization
• Define the problem statement or describe the incident
• Describe the process
• Identify the right problem
• Investigate the potential causes by using the tools taught in the class
• Collect relevant data
• Use check sheets and other methods you learned
• Create sample surveys or interviews
• Use an appropriate method to analyze the data
• Develop an action plan

Root Cause Analysis Training For Engineers