Incident Root Cause & Failure Analysis – RCFA

SCHEDULE

Dates	Venue	Category
16-17 May 2023	Bangkok – Thailand	Maintenance-Technical
16-20 October 2023	Port Moresby – Papua New Guinea	Maintenance-Technical
23-27 October 2023	Kuala Lumpur – Malaysia	Maintenance-Technical

INTRODUCTION

RCFA training, Root Cause Failure Analysis training provides the concepts needed to effectively perform industrial troubleshooting investigations. RCFA Training covers the methodology to perform Root Cause Failure Analysis, Failure Modes and Effects Analysis (FMEA), Fault Tree Analysis (FTA), and other hot topics currently in maintenance engineering.

RCFA Training also includes detailed design and troubleshooting guidelines, investigating techniques for system failures, which are needed to perform problems found in most production facilities. Root cause failure analysis helps you to identify what, how and why something happened, thus preventing recurrence. Root causes can be controlled by management and allow for generation of recommendations.

Root Cause Failure Analysis is a powerful tool you can use to focus on the source of the equipment failure to prevent future failures.

Learn the techniques and methods on why an event occurred and the keys to developing effective recommendations, data collection, charting, root cause identification and recommendation generation and implementation.

BENEFITS OF ATTENDING

Upon the completion of this training, participants will be able to:

• Identify common manufacturing errors and deviations
• Identify the origin of a problem, determine what happened, why it happened and figure out what to do to reduce the likelihood that it will happen again
• Compare common root cause analysis tools and methods such as events and casual factor charting, change analysis, barrier analysis, tree diagrams, why-why chart,  petro analysis, storytelling method, fault tree analysis, failure modes and effect analysis, reality charting and other methods
• Use Failure Modes and Effects Analysis (FMEA) techniques (DFMEA and PFMEA)
• Learn when and how to use Fault tree analysis (FTA) as a top down, deductive failure analysis
• Learn when to use  cause and effect Fishbone (Ishikawa) diagram
• Gain insight on basic types of causes: physical, human and organizational causes
• Describe how to prioritize failure events to analyze, preserve failure data, and order a failure analysis
• Describe systems failure analysis methods and techniques
• Develop and implement effective and efficient root cause failure analysis programs
• Assess how to make RCFA a structured, team based, analytical approach
• Understand fundamental problem solving processes
• Examine the basic concept of problem solving, and how to facilitate an effective investigation
• Gain fundamental problem solving processes and techniques for effective investigation
• Gain working knowledge of many modern methods and techniques
• Gain real world skills on effective methods for critical thinking, creative solutions and corrective actions
• Assess the personal strength you need to perform incident investigation, charting and reporting

WHO SHOULD ATTEND?

• Engineers, Technician, analysts, Production supervisors, production lead personnel, quality engineers, manufacturing engineers, manufacturing managers, contract administrators, procurement personnel, procurement specialists, project managers, project engineers, design engineers, MRB engineers and program managers should attend this training.

COURSE OUTLINE

Session 1: What is Root cause analysis (RCA)?

• Systems Failure Analysis
• What is the problem?
• Defining the problem
• The nature of a problem
• Problems versus symptoms
• Clearly define problem and analysis boundaries
• Product and process nonconformance
• Differences between Root Cause Analysis and Root Cause Failure Analysis (RCFA)

Session 2: Introduction to Root Cause Failure Analysis

• General Analysis Techniques
• What is Root Cause Analysis?
• Root Cause Analysis Techniques
• Root cause failure analysis methodology
• Safety-related issues
• Regulatory compliance issues
• Process performance
• System and component considerations
• Change and barrier analysis
• Events and causal factors analysis
• Structured Root Cause Analysis techniques
• Problem identification
• Problem description
• Cause analysis
• Determine Root Cause
• What are the types of causes?
• Causal factor category list
• Determine causes of event
• Solution development
• Practical Problem Solving
• Tools for Root Cause Analysis
• Right tool and method
• Manufacturing Case
• Methods to define and verify root causes
• Tools for developing practical solutions
• Techniques for implementing corrective action
• Assessment and assignment matrix
• Failure Modes and Effects Analysis (FMEA) techniques (DFMEA and PFMEA)
• Fault tree analysis (FTA) as a top down, deductive failure analysis
• Effect Fishbone (Ishikawa) diagram

Session 3: Introduction to Fault Tree Analysis (FTA)

• Design of experiments and systems failure analysis
• Nature Of cause
• Identify, collect, and evaluate relevant data
• Brainstorming and mind mapping
• Human and system reliability
• Analysis pitfalls
• Team assignment
• Common root cause analysis tools
• Select/tailor analysis tools and techniques
• Taguchi fractional factorial
• Corrective action
• Conduct interviews and small-group brainstorming sessions
• Identify major contributors to problem occurrence
• Tools & Techniques – Flowcharting
• Develop ranked list and rationale for potential root causes
• Document and review results
• Evaluate each major contributor using a hierarchical structure of root cause categories
• Allocate performance measure losses to root cause categories
• Failure classification

Session 4: Failure modes and effects analysis (FMEA)

• FMEA
• Design and Process FMEA
• Ordering the analysis team
• Analyze the data: Introducing the logic tree
• Identification of Root Cause Failure Analysis and Cause
• Fault tree analysis
• Failure cause evaluation and statistics

Session 5: Fishbone (Ishikawa) Diagram

• Cause–and–Effect Diagram
• Ishikawa Diagram
• Cause enumeration diagram, process fishbone, or time–delay fishbone
• CEDAC (cause–and–effect diagram with the addition of card
• Desired–result fishbone
• Reverse fishbone diagram
• Possible causes for an effect or problem
• When and how to Use a Fishbone Diagram
• Identifying possible causes for a problem or problems
• Effect of Methods, Machines (equipment) and People (manpower)
• Effect of  Materials, Measurement and Environment
• Fishbone Diagram examples
• How to create a Fishbone Diagram
• Analyze process dispersion
• Result and Analysis of Causes and Effects

Session 6: People, Processes and Organizations

• The role of people and processes
• Role of Management Systems
• Understanding the roles that people typically play in problem solving
• Define new roles
• An introduction to the process
• When, where, why, and how to apply the process effectively

Session 7: Process for Finding Root Failure Cause

• The Framework
• Methods of data collection
• Reliance on expertise
• Clues for finding root cause
• Testing and verification of causes
• Assignable Cause and Root Cause Analysis
• The Importance of Establishing Codes for Tracking and Trending of Investigations
• Link between system and component
• Formulating and amplifying the problem
• Identifying solutions
• Failure Mode and Effect Analysis (FMEA)
• Writing Troubleshooting guides

Session 8: Root Cause Failure Analysis (RCFA) Process

• RCFA as a simple, yet disciplined process
• Why did it happen?
• Could it have been avoided?
• How can it be prevented in the future?
• Investigate, rectify and eliminate equipment failure
• Chronic breakdowns
• How to find the latent roots responsible for the breakdown
• Latent roots and the management system weaknesses
• Preserving Failure Data
• Ordering the Analysis
• Analyzing the Data
• Communicating Findings & Recommendations
• Tracking for Success
• Stating the Failure Event
• Stating the Failure Modes
• Hypothesizing
• Verifying Hypotheses
• Determining Underlying Causes (Physical, Human and Latent)

Session 9: Corrective Action

• Criteria for event description
• Cause and effect analysis corrective action definitions
• Corrective action order of precedence
• Advantages and disadvantages of design modifications, process modifications, procedural modifications, requirements relaxation, screening, and other potential corrective actions
• Evaluating corrective action effectiveness. Inspection caveats
• Corrective action class exercise.
• Corrective Action Requirements.
• ISO 9001 root cause identification and corrective action requirements
• The ISO 9001 Management Review
• Pareto analysis
• Material review, disposition, and corrective action
• Material review, disposition, and corrective action class exercise

Session 10: Conducting a Cost-Effective Root Cause Failure Analysis

• Root Cause Failure Analysis facilitator
• Root Cause Failure Analysis team leader
• The process expert on conducting a root cause analysis
• The content matter expert pertaining to the event
• Develop a root cause analysis reporting
• Contributory Factor
• Corrective Action
• Person(s) Responsible
• Action Due Date
• Measurement Technique
• Establishing A Value Criterion
• Pick a Cause
• Grab-bag Analysis
• Criteria to compare root cause analysis systems
• Completeness
• Comparability
• Cost-effectiveness
• Growth potential
• Practice Description
• Opportunities for Impact
• Evidence for Effectiveness of the Practice
• Potential for Harm
• Costs and Implementation
• Automating Root-cause Analysis
• Requirements for Analyzing Failure Modes and Their Effects
• Analysis Capabilities in Event Management Systems
• Event Filtering
• Rule-Based Event Analysis
• Model-Based Event Analysis
• Codebook Correlation

Session 11: Strategies and Solutions for Root Cause Analysis

• Process is the key
• Tools and techniques are essentials
• Technique and tools to develop and implement effective & efficient Root Cause Analysis programs
• Tools & techniques to identify manufacturing errors
• Tools and techniques to trouble shoot
• Addressing the challenges of t Root Cause Analysis investigations
• Tools and techniques for identifying common Root Causes and implementing corrective actions
• Manufacturing investigations techniques
• Managing corrective action and preventive action