Root Cause Analysis Training Crash Course

Root Cause Analysis Training Crash Course

The first goal of Root Cause Analysis (RCA) is to discover the root cause of a problem or event.

The second goal of Root Cause Analysis is to fully understand how to fix, compensate, or learn from any underlying issues within the root cause.

Sounds simple, but accomplishing these two goals can have a profound impact on organizations. Benefits include:

⦁ Improving team members’ communication
⦁ Help organizations better understand their customers’ needs
⦁ Saving organizations time and money by preventing issues from reoccurring

Additionally, RCA can help organizations of all kinds build a foundation for continuous improvement by identifying opportunities for process improvements as well as promote knowledge sharing within an organization by documenting the investigation process and findings.

Due to its many tools, RCA is now used in many different industries, including:

• IT and telecommunications
• Healthcare
• Systems analysis
• Manufacturing/Industrial process control

In manufacturing, root cause analysis methods allow the control of quality in the production of chemicals in the industrial process control discipline.

In systems analysis, RCA has been successfully applied to change management or risk management areas. Root cause analysis is also receiving high marks for analyzing businesses, determining their goals, and creating processes to reach those goals, making it ideal for system analysis.

In healthcare, RCA examines events to determine root causes of problems that have led to undesired outcomes such as harm to patients or medication side effects. The analysis is utilized to improve patients’ safety, take corrective measures to prevent future occurrence of such events.

The IT and telecommunications sectors are also zeroed in on RCA. The methodology of root cause analysis helps detect the root causes of newly-surfaced problematic services or deal with recurring problems. The analysis is widely used in processes such as incident management, security management, etc.

Root Cause Analysis Training Crash Course Description

Root cause analysis training crash course covers the methods, concepts, and principals of the root cause analysis investigations. Root cause analysis (RCA) techniques serve problem-solving purposes, assisting you to determine the root causes of failures and issues in order to solve or inhibit them.

The root cause analysis training crash course will also teach you to create and implement suitable corrective action plans immediately after the causes of a failure are identified. The root cause analysis is known as one the most effective quality methods applicable in both simple and complex processes.

Root cause analysis training crash course helps you to trace problems down to the root cause. This “reverse” methodology is ideal for the conditions where there is more than one essential cause associated with a problem. Although multiple causes are sometimes independent from each other, they often are connected to each other. In such cases, eliminating one cause will lead to resolving the whole issue. Root cause analysis training crash course will teach you how to identify all the causes there, explore their relationship with each other, their impacts on the system, eliminate them, and set up preventive actions to avoid the same problems from reoccurring in future.

Why Do You Need Root Cause Analysis Training Crash Course?

• You will learn how to identify the underlying problem
• You will learn how to determine the most crucial cause having the most sever effect
• You will learn to develop successful corrective action and preventive plan for the identified problems to avoid them from happening again

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 Crash Course Features

• TONEX root cause analysis training crash course contains labs, in-class activities, hands-on workshops, case studies, and practical exercises.
• TONEX root cause analysis training crash course is fun, interactive, and dynamic.
• During the TONEX root cause analysis training crash course, students bring in their own projects and through our coaching, conduct a thorough root cause analysis.

Audience

Root cause analysis training crash course is a 4-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
• Quality personnel
• R&D team
• Production engineers and managers
• Design team

Training Objectives

Upon the completion of Root cause analysis training crash course, the attendees are able to:

• Comprehend the theory of root cause analysis and how it functions
• Define problem statement in an unambiguous way
• Use appropriate methods for gathering data
• Explain all the steps of root cause analysis
• Apply brainstorming tools to determine all possible causes
• Use brainstorming tools to produce ideas for solutions
• Discuss all the benefits and drawbacks of each solution to figure out the best and the most efficient one
• Watch the implemented solution(s) to assess its effectiveness
• Derive an efficient action plan
• Derive a successful preventive plan
• Recognize common limitations of root cause analysis and find approaches to remove those barriers
• Build “whys” and “hows” trees
• Think creatively to explore all the causes of a problem
• Construct an effective work environment
• Enhance their problem solving skills by deriving analyzing models for multilayers engineering problems
• Describe the problem solving procedures
• Use proper and suitable methods of data collection fit the nature of each problem
• Apply the root cause analysis tools successfully
• Figure out when to use analytical thinking methods and when creative thinking techniques
• Provide sufficient problem solving support
• Search through the possible root causes of a failure that is beyond a quick fix
• Track the chain of the events to reach the real cause of a failure
• 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 (Can be customized, optional modules)

Overview of Root Cause Analysis

• Definition of Root Cause Analysis (RCA)
• Origin and evolution of RCA
• Why RCA is important
• Applications of RCA
• Benefits and limitations of RCA
• Data gathering
• Analytical vs creative thinking
• Content vs process thinking

How to Master in Problem Solving?

• First step; detecting the right problem
  • Defect Creation
  • Physics of Failure
  • Human Factors
  • Life Cycle Gaps
  • Hidden Failures
• Failure modes during the production or of equipment
• How does reliability engineering describe failure?
• Prioritizing tools
• Developing problem statement, thoroughly and efficiently
• Problem solving practices
• Causes, their levels, their severity
• Identify the underlying causes
• Tackling the problems proactively
• Practices to exploring the problem
  • Inclusive study of the Problem
  • Advantages of using flowcharts
  • How to use flowcharts
  • How to use checklists
  • How to study critical incidents
  • How to generate performance matrices and how to efficiently use them

Problem Solving Process

• Discovering the problem from the symptoms
• Defining problems, inclusively and efficiently
  • Systematic methods
  • Fish Bone Diagrams / Ishikawa/ Cause and Effect diagrams
• Investigating the situation
• Collecting the required information
• Determining solutions requirements
• Generating creative solutions
  • Brainstorming
  • Reverse Brainstorming
  • Imagineering
  • SCAMMPERR
  • Mind Mapping
  • De Bono’s  6 Thinking Hats.
• Evaluating your options
  • Pro’s and Con’s
  • Force field analysis
  • Cost/Benefit Analysis
  • Feasibility/Capability Analysis
• Choosing the best solution
• Putting the selected solution in action
  • Creating an action plan
  • Breaking complex solutions into small, simple action steps
  • Prioritizing actions and assign roles
  • Following up at milestones
  • Monitoring the effectiveness of the process
• Reviewing the effect of the solution on solving the problem
• Measuring the solution effectiveness

Brainstorming

• How to brainstorm effectively?
• What are the principals of brainstorming?
• Notions and components of brainstorming
• How to prepare for a brainstorm session?
  • Clarifying your focus topic
  • Organizing your team
• How to lead a brainstorm session
• What has changed in the advanced technique?
  • Problems with the conventional method
  • Advanced brainstorming is a better brainstorming
• How to brainstorm alone?
  • Times you need to brainstorm on your own
  • How to use advanced brainstorming to brainstorm by yourself

Fishbone Diagram Procedure

• How to begin
• Directions
• Approaches to build the “bones”
  • The 6Ms
  • The 5 Whys
  • The 4Ps
• Steps to generate a fishbone diagram
• How to get everybody in the team engaged in generating causes
• How to complete your fishbone diagram?
• How to present your fishbone diagram?

 Creative Thinking Techniques

• What is creativity?
• What is creative thinking?
• How creative thinking relates to root cause analysis?
• How do creative thinking techniques work?
• How can creative thinking result in generating new ideas?
• How to apply creative thinking in brainstorming sessions
• Advanced tools of creative thinking
  • Computer-based methods
  • Manual methods
• Creating a creative environment impacts root cause analysis investigations

Comprehending the Root Cause Analysis Process

• How every problem can lead to a process failure
• Using Suppliers, Inputs, Process, Outputs, and Customers (SIPOC) to define boundaries and interrelationships
• How can flow-charting get you to the right place of the process

Failure Modes Effect Critical Analysis (FMECA) Techniques

• Hardware approach
  • Analyzing the failure modes of each individual hardware
  • When items can be analyzed separately
  • It’s a bottom-up method
• Functional approach
  • Identify and analyze each item based on their functionality
  • When items cannot be analyzed separately
  • It’s used when the process is designed and functional block diagrams are developed
• What is a functional block diagram?

Failure Modes

• Failure definition
• Failure modes categories
  • Complete failure
  • Partial failure
  • Intermittent failure
  • Function out of specification
  • Unintended function
• Latent failure modes
• Hidden causes of failure
• The effects of the causes
• Failure mode identification
• Assembly, sub-assembly, parts
• Failure description
• Alarming signs
• Techniques of failure detection
• All potential effects on assembly and on complete product
• Failure modes practices

Analysis and Prioritization Techniques

• Analysis models
  • Analyzing the situation
  • Decision assessment
  • Priorities to take action
  • Analyzing problems
• Organized techniques to problem solving
  • Methods of analysis
  • Gathering relevant information
  • Stating the limitations and restrictions
  • Applying stair-step method to break down complex problems
• Decision analysis
  • Selecting the best among all options
  • Setting objectives
  • Associating weight to each objective to make the best decision
  • Coming up with a pleasure metric to decide among options

Digging for the Root Causes

• Five ways to detect all hidden causes
• Three approaches to select or ignore the causes
• Fault tree evaluation method
• Using cause-and-effect diagrams to organize all the causes
• Tools for problem cause brainstorming
  • Problem cause brainstorming
  • The intention and practice of brainstorming
  • Brainstorming Recording Templates

Gathering Required Data

• Problem cause data gathering methods
• Taking advantage of the documented data
• How to use the operational logs
• Step-by-step sampling
• Similarities and differences of population and sampling
• Using check sheets, graphs, and tables
• Benefits of using surveys, interviews, and field observation to gather opinions
• Problem cause data collection checklist

Analyzing and Evaluating the Obtained Data

• Learning how to evaluate data objectively
• Tools for analyzing hard data
  • Run charts
  • Histograms
  • Pareto diagram
  • Modified scatter diagram
  • Pivot tables
• Tools for analyzing soft data
  • Affinity diagrams
  • Relationship diagrams
• Integrative data analysis tools

Human-Based Causes

• Analysis methods
• Recognizing the human-based causes and recommending effective solutions for them

Getting Rid of the Root Cause Permanently

• DeBono’s Six Hats

Facilitation Abilities

• Process facilitation vs content expert
• Facilitation and interference choices

Expanding the Use of Data

• 3 dimensional variables
• Highlighting the essential elements
• Data comparisons practices

Statistical Analysis

• How to perform t, F, and ANOVA tests
• How to use Excel for statistics
• Chi-square approach

Where Does Management Stand in the RCA Process

• Management emotional and subjective biases impacts
• Organizational ecosystem effects
• Supportive responses matter

Exercising the Best Solution

• Establishing the execution steps
• Developing an action plan
• Using tree diagrams
• Welcoming, embracing, and accepting change
• Preparing for modifications
• Force-field analysis method

TONEX Hands-On Workshop Sample

• Define the problem statement
• Describe the process
• Determine the underlying problem
• Investigate the potential causes by using the tools taught in the class
• Gather relevant information
• Use check sheets
• Create sample surveys or interviews
• Evaluate the data
• Brainstorm a list of solutions
• Eliminate solutions until you have a final solution
• Develop an action plan based on your recommended solution
• Develop a preventive plan

Root Cause Analysis Training Crash Course