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Root Cause Analysis (RCA) Training

Root cause analysis (RCA) training teaches you the rational behind the RCA process, the techniques, tools, and strategies associated with RCA implementation. TONEX offers several training courses suitable for all kinds of businesses and industries.

Root Cause Analysis (RCA)

Root Cause Analysis (RCA) is a proactive quality methodology that addresses an issue or a non-conformance to get to the bottom of the problem. RCA method is specifically to correct or remove the cause, and inhibit the problem from recurring.

Root Cause Analysis

In a simple word, RCA is the application of a chain of recognized, common sense approaches and tools generating a systematic, calculated, and documented method to the detection, comprehending, and resolve of the underlying causes.

Why Root Cause Analysis is Important?

  • Short-term solutions are not effective in a long period of time. They require repeating the same tasks over and over again for similar problems. Handling issues with short-term solutions is not a trusted formula for profitability and organizational growth.
  • You enhance efficiency and effectiveness by taking the sufficient time to think through problems from first principles, and then confronting the causes instead of the effects.
  • Searching below the surface to the root of a problem or issue is necessary to profitability and efficiency. By observing the surface symptom of a problem and eliminating what has caused it to happen, you initiate an inhibitory solution that will stop the problem permanently. In order to deeply comprehend the real source of a problem, you need to start a root cause analysis.
  • Eliminating the root cause saves your time and money

QM&T Approach to RCA

  • The first step is to identify the problem. QM&T observe many angles of the organization, and can identify potential problem areas. This process is known as Pareto Analysis.
  • The Corrective Action Request (CAR) system is applied to record the immediate and long-term corrective actions.

RCA Tools & Techniques

5 Why’s (Gemba Gembutsu)

  • 5 Why’s, aka Gemba Gembutsu, means Place and Information in Japanese.
  • 5 Why’s usually refers to the exercise of asking, five times, why the failure has happened to reach down to the root cause/causes of the problem.
  • No specific method is required, but the outcome should be presented in the Worksheet
  • 5 Why’s are best used tool in a simple RCA

Pareto Analysis

  • Pareto analysis helps you select the most effective changes to make
  • It’s based on the Pareto principle, the rationale of which is that by doing 20% of the work you can produce 80% of the benefit of doing the whole job.
  • Pareto analysis is a formal method to look for the necessary changes to achieve the biggest benefits. It is useful where many plausible actions are available.

Fishbone Diagrams

Also known as Ishikawa diagrams, is applied for more complicated RCAs. This is a way to brainstorm all the possible processes and factors that could contribute to a problem.

Process Analysis, Mapping and Flowcharts

  • Flowcharts establish information about a procedure in a visualized way to make it clear that what is affected.

Fault Tree

  • This is a graphical technique to present an organized explanation of the mixtures of possible incidences in a system, which can lead to undesirable result. This method can combine system and human failures

Check Sheets

  • Check Sheets (or Tally Charts) are applied to collect and document data.

Control Charts

  • The control chart is a diagram to investigate how a process changes over time. Data is in time order. A control chart has a central line for the average, an upper line for the upper control limit and a lower line for the lower control limit. These lines are derived from historical data. By comparing current information to these lines, you can have an idea about the consistency of the process

Quality Planning

  • Every stage of a process or can be a potential source of failure. Quality planning anticipates these sources and arrange for preventing them from occurring.

RCA Drawbacks

  • Not understanding the problem and therefore not defining it correctly
  • Not asking for help
  • Not considering all possible failure modes/causes
  • Not identifying all root causes
  • Not understanding how the system should operate Runaway tests and analysis
  • Adopting a ‘remove & replace’ mentality
  • Silver Bullet Theory
  • Returning the part/product without analysis Failing to follow-through
  • Jumping to conclusions (satisficing)
  • Tearing a system apart without a plan

Learn About:

  • Problem solving tools
  • Identifying all the potential causes
  • 5Whys
  • FMEA
  • Pareto analysis
  • FTA
  • Bayesian inference
  • Ishikawa (fishbone) diagram
  • Cause Mapping
  • Barrier analysis
  • Change analysis
  • Causal factor tree analysis
  • Data gathering tools
  • Analyzing the collected data
  • Human factors
  • Root cause elimination
  • Using data
  • Statistical hypothesis
  • Developing corrective and preventive actions

Root Cause Analysis (RCA) Training

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