Length: 2 Days
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Root Cause Analysis for Manufacturers

Root Cause Analysis (RCA) for Manufacturers training course will teach attendees to identify the cause of a problem, solve it, and prevent it from occurring again. RCA saves manufacturers and system integrators valuable resources, time, and money by optimizing their troubleshooting system and implementing root cause analysis basics.

Root cause is the fundamental, underlying reason for a problem. Many manufacturers might only treat an issue’s symptoms, or even its intermediate causes, without fixing the root problem. RCA helps with process improvement and makes improvement for less waste and redundancy within your operations.

Toot Cause Analysis (RCA) course will enable participants to understand root cause analysis and the process of investigating the root causes of why defects are present within a manufacturing process or product and determine what can be done to solve or prevent them. Participants will gain a working knowledge of RCA process, methodologies, tools, and best practices.

Who Should Attend?

This course is designed for technicians, engineers, testers, integrators, operators, maintenance, analyst, quality, reliability, safety, process employees with little or no Root Cause Analysis (RCA) experience. The course is also useful for those who have experience with RCA but have never had any formal training on the standard.

Course Structure

Lectures, hands-on and problem solving practices using simple tools and methodologies. The course is designed to provide the participants with tools and best practices to analyze complex systems (system manufacturing, integration and operation) to identify the root causes of problems.

  • Comprehensive RCA Training Course Manual
  • RCA Cheat Sheet
  • Tonex’s Root Cause Analysis Tools, Techniques and Templates (Excel Tools and RCA Templates Provided)
  • Core of Problem Solving and Corrective Action

What You Will Learn

  • An overview of the Root Cause Analysis (RCA).
  • A summary of RCA tools and applications.
  • An overview of problem solving techniques.
  • RCA process, methods, their strength, and their effectiveness in dealing with the complexity of complex manufacturing and system integration/operation processes.
  • Using RCA tools and methodologies including Fishbone diagram, 5-Whys, Cause and Effect Analysis, Event Tree Analysis (ETA), Fault Tree Analysis (FTA), Failure Mode Affect Analysis (FMEA) and others.

Course Agenda/outline

Fundamentals of Root Cause Analysis (RCA)

  • Root Cause Analysis for Manufacturers
  • Benefits of Root Cause Analysis
  • How to Conduct Root Cause Analysis
  • Manufacturing Problem Solving Models
  • Root Causes and Realistic Solutions
  • Core Principles of Operational Efficiency
  • Analytical and Creative Thinking

Root Cause Analysis (RCA) Methods

  • Working with Qualitative RCA Tools
  • Fishbone Diagram: Cause and Effect Diagrams 5 Why, Concentration Diagrams
  • Working with Quantitative RCA Tools
  • Capability Analysis, Control Charts, MSA, and Regression Analysis
  • Corrective Action Strategies
  • Correlating Process and Product Variables, and Poke Yoke
  • Control Charts
  • Brainstorming
  • Cross-functional Team Building
  • The Basic Method
  • Basic RCA Procedure
  • Defining Area of Concerns
  • Collect all Relevant Data about the Problem
  • Analyze the Information for Evidence of all Root Causes
  • Develop or Recommend Strategies for Handling the Problem
  • Implement Solutions as Needed
  • Case Study 1
  • Activity 1: Working with RCA Methods

The Fishbone Diagram

  • Ishikawa Diagram
  • Fishbone Diagram: “Cause and Effect” Diagram
  • Manufacturing, System Integration and Operation Issues
  • Ways to Examine the Causes and Effects
  • Catalysts and Gleaning Ideas
  • Fishbone Procedure
  • Inefficiency in your Manufacturing and Operational Structure
  • Identifying Root Cause to the Defects
  • Finding Intermediate Causes
  • Variation in the Process
  • 6M’s (5 M’s and 1 P)
  • Six Elements Contribute to Variation in a Process
  • Machine, Material, Method, Measurement, Mother Nature “Environmental” and Man (People)
  • Case Study 2: Using Easily Understood Visual of the Potential Root Causes of a Nonconformance
  • Activity 2: Brainstorming – Working with Fishbone Diagram

The Five Whys (5 Whys)

  • The Five Whys Technique
  • Benefits of the 5 Whys
  • An Effective Method for Determining Root Causes
  • To Identify the Root Cause of a Problem
  • Determine the Relationship between Different Root Causes of a Problem
  • Easy to Complete without Statistical Analysis
  • When Is 5 Whys Most Useful?
  • When Problems Involve Human Factors or Interactions
  • How to Complete the 5 Whys
  • Case Study 3: Keep Asking Why- Discovering Relationships between Various Root Causes of a Single Nonconformance,
  • Activity 3: Working with 5 Whys Method

8D Method

  • Root Cause Analysis (RCA) and the 8D Corrective Action Process
  • Effective problem-solving method is the eight disciplines (8D) model,
  • Identifying, Correcting, and Eliminating Recurring Problems
  • 8D for Product and Process Improvement
  • 8D approach and Permanent Corrective Actions based on Statistical Analysis of the Problem
  • Source of the Problem by Determining its Root Causes
  • Case Study 4: Root Cause Analysis and the 8D Corrective Action Process, Real-life Experience with Actual Examples from Manufacturing, Engineering, System Integration and Operation
  • Activity 4: Working with 8D

Overview of Other Approaches to Root Cause Analysis

  • Event Tree Analysis (ETA)
  • Fault Tree Analysis (FTA)
  • Failure Mode Affect Analysis (FMEA)
  • Events and Causal Factor Analysis
  • Change Analysis
  • Barrier Analysis
  • Management Oversight and Risk Tree
  • Kepner-Tregoe Problem Solving and Decision Making

Workshop 1: Apply RCA Techniques to a Real Problem Defined

  • Problem Definition
  • Factor that Caused a Nonconformance
  • The Process
  • Problem Identification Components
  • Defect Creation
  • Physics of Failure
  • Human Factors
  • Life Cycle Gaps
  • Hidden Failures
  • Production and Equipment Failure
  • Reliability Engineering and Failures
  • Identifying Possible Causes
  • Eliminating the Underlying Cause(s)
  • Preventing Reoccurrence
  • DeBono’s Six Hats
  • Data Collection and Data Analysis Tools
  • Analysis of Human Errors
  • Management and Organizational Issues
  • Policy Issues


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