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Engineering RCA Training By TONEX

Engineering RCA training, root cause analysis course 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.

Engineering RCA training, root cause analysis course for engineers

Engineering RCA 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.

What are Root Cause and Root Cause Analysis (RCA)?

A root cause is the highest level of a problem. It is the “the evil at the bottom” that begins the whole cause-and-effect chain leading to a problem. In other words, root Cause is an element caused an undesirable and non-compatible incident that needs to be eliminated and avoided in the future. One might always remember that removing a cause doesn’t automatically prevent its recurrence within certainty. In order to avoid it in the future, a complete preventive action plan should be developed.

Root Cause Analysis is called to a series of approaches, tools, and techniques applied to identify causes of problems. Depending on the nature, location, and severity of a problem/incident, various methods of root cause analysis can be used.

Purpose of Engineering RCA

  • To identify the factors that led to un-conformant outcomes in industrial fields.
  • To understand what behaviors, actions, inactions, or conditions have to change or stop.
  • To prevent recurrence of similar damaging results
  • To learn lessons that can improve the achievement of better consequences.

General Principals of RCA

  • An effective RCA is a systematic one. It has to be done through careful investigation with strong evidence and documents supporting the identified causes
  • In the cases that more than one root cause exists, determined and sustaining efforts should be done to investigate all the root causes
  • The reason why all the possible solutions to a problem need to be presented is to prevent the reoccurrence of the problem at the most economical way and as early as possible. Therefore, always the simplest and the least expensive solution should be chosen, if there are multiple options.
  • Since the identified root causes vary with the definition and nature of a problem, a clear and effective problem statement or incident description is crucial to ensure the appropriate analysis is conducted.
  • Root causes can be categorized based on including a specific cause. This can happen because a logical approach of identifying root causes is by applying hierarchical clustering data mining solutions
  • In order to conduct an effective and successful analysis, a chain of events or timeline should be considered. This can help in understanding the relationships between causal elements, root cause(s), and the problem to be investigated
  • An ideal RCA is the one that reduces the possibility of the problem reoccurrence
  • RCA requires change. Change often comes with resistance. In order to be able to implement an effective RCA, a supportive leadership, culture, and policy is required.

Corrective Action Based on RCA

  • Define the problem or describe the incident as clear as possible
    • Specify the nature, the severity, the location(s), and the timing
  • Collect data and evidence
    • Categorize them based on the timeline they occurred
    • For every behavior, condition, action, and inaction, state what needs to be done and changed to prevent them fro happing again
  • Use clustering groups when you do hierarchical data mining
    • Select the groups that share a specific cause
    • Spot their upper-groups
    • Identify the group specifications that repeated consistently
    • Validate them with experts
  • Use the “whys” techniques to identify all the causes associated with each level towards the target problem
  • Categorize the identified causes into two classes:
    • Casual factors, related to an incident in the sequence
    • Root causes that intermitted in that step of the chain after eliminated
  • Search for solutions that:
    • Inhibit the problems from happening again with a good certainty
    • Are within the organizational control
    • Meet the objectives
    • Don’t cause other new and unpredicted problems
  • Implement the recommended correction(s) for the identified root causes
  • Observe their effectiveness in operation

RCA Limitations

  • RCA effectiveness depends on the input data and the skill of the RCA team in using data
  • Human factors are significant in executing RCA
  • RCA can often be very time consuming, especially during the data gathering

RCA Techniques

  • The “5 whys”
  • Barrier Analysis
  • Change Analysis
  • Fault tree analysis
  • FMEA
  • Fishbone diagram
  • Pareto analysis

Engineering Fields Benefit from Engineering RCA Training:

  • Oil and Gas
  • Mining
  • Steel
  • Automotive
  • Energy
  • Manufacturing plants
  • Repetitive Manufacturing
  • IT
  • Aerospace
  • Chemical plants
  • Parts manufacturing
  • Bioengineering

Audience

Engineering RCA training, root cause analysis course 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

What Will You Learn?

Below are the major topics are covered in engineering RCA training (more detail can be found under the full course description):

  • Overview of Root Cause Analysis (RCA)
  • Practical Problem Solving
  • Understand the Process
  • Figure Out All Potential Causes
  • Data Collection
  • Data Analysis
  • Accidents Analysis and Role of Human Error
  • Root Cause Elimination
  • Facilitation Skills
  • Going Deep with Data
  • Statistical Hypothesis
  • Management Behaviors Affecting RCA Studies
  • Solution Implementation
  • TONEX Hands-On Workshop Sample

Engineering RCA Training By TONEX

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