Root Cause Failure Analysis

( Duration: 2 Days )

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

RCFA course 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.

Technician, 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.



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

Introduction to Fault Tree Analysis

  • 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
  • Failure modes and effects analysis (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

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

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

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

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)

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

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

Strategies and Solutions for Root Cause Analysis

  • Process is the key
  • Tools and techniques are essentials
  • Technique and tools to develop and implement effective and efficient Root Cause Analysis programs
  • Tools and 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

Data Analyzing

  • Analyzing data
  • Causal factor charting
  • Fault tree analysis
  • Using fault tree analysis
  • Change analysis
  • Determining root causes

Applying Apollo Root Cause Analysis Method

  • ARCA approaches
  • Problem Definition
  • Cause and Effect
  • Charting
  • Application
  • Solutions

Encarta Labs Advantage

  • One Stop Corporate Training Solution Providers for over 3,500 Modules on a variety of subjects
  • All courses are delivered by Industry Veterans
  • Get jumpstarted from newbie to production ready in a matter of few days
  • Trained more than 20,000 corporate candidates across india and abroad
  • All our trainings are conducted in workshop mode with more focus on hands On

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Contact us for delivering this course as a public/open-house workshop for a group of 10+ candidates at our venue