Maintenance Root Cause Analysis

About the Course

Maintenance Root Cause Analysis (RCA) is a process of identifying and addressing the underlying causes of issues. It is among the most crucial elements of problem-solving in quality management. This training program will teach delegates the step-by-step process of delivering RCA, from identifying the problem to implementing control measures. They will be able to conduct an RCA that always ensures success.

Solving problems and implementing improvements doesn’t happen by chance: it requires a thorough and methodical process and a set of skills to identify, solve, and prevent problems at the point of origin.  Without a doubt, RCA is often missing from most businesses, and these tools and skills apply to all industries and are recognised as core components of complex problem-solving. 

This 5-day Maintenance Root Cause Analysis training course is specifically aimed at developing your talents in the latest RCA technologies with direct application to the workplace. The main aim of the course is to deliver fundamental knowledge and a comprehensive set of skills to produce professionals capable of transforming an organisation’s problem-solving strategy and delivering excellent solutions. It addresses the significant need for managers and leaders to understand the need for RCA, who can conduct deep-rooted investigations and troubleshoot intricate problems to attain acceptable solutions.

Core Objectives

The delegates will achieve the following objectives:

• Know the history of RCA
• Understanding the RCA Terminology, Goals, and Benefits
• Investigate RCA utilising different quality tools
• Define problem solving models including 8D, PDCA, and DMAIC
• Understand how organisations solve problems using RCA
• Optimise maintenance strategies with continuous improvement procedures
• Evaluate your current practices of RCA
• Understand failure modes and problem-solving techniques
• Working with various data collection plans and methods
• Identify the most common challenges of RCA

Training Approach

This training course will consist of presentations with interactive exercises supported by lecture presentations, video material, and applicable group case studies, including personal and professional experiences. The delegates will be persuaded and motivated to actively participate in group conversations while continuously being asked open-ended questions related to the subject matter and the applicability of information to meet workplace demands. 

The Attendees

This training course will be helpful to almost anyone as the skills covered are valuable when understanding the RCA and how it impacts maintenance solutions.

It is suitable for a wide range of professionals but will greatly benefit:

• Maintenance Managers, Supervisors, and Superintendents
• Stakeholders in the Maintenance Functions of RCA
• Reliability and Quality Systems Engineers
• Maintenance and Asset Key Users
• Safety and Integrity Professionals
• Operational Professionals who are interested in Quality Problem-Solving
• Other Professionals Involved in Continuous Process Improvement

Daily Discussion

DAY ONE: INTRODUCTION TO MAINTENANCE ROOT CAUSE ANALYSIS

• Introduction to RCA
• History of RCA and Roots Traced to TQM
• The Four Phases for Resolving RCA Problems
• The Positives and Negatives of Using RCA
• Conducting RCA Methods and Processes
• Steps to Resolve RCA Problems
• Typical Duration of RCA to Complete
• What are some challenges faced during RCA’s?

DAY TWO: TOOLS AND TECHNIQUES FOR ROOT CAUSE ANALYSIS (RCA)

• The Five (5) Why’s Techniques
• Pereto Analysis (80/20 Rule)
• Failure Mode and Effects Analysis (FMEA)
• Fault Tree Analysis (FTA)
• Cause and Effect Point
• Nominal Group Techniques
• Poka-Yoke (Mistake Proofing)
• Barrier (Isolation) Analysis

DAY THREE: DIFFERENT APPROACHES AND TECHNIQUES OF ROOT CAUSE ANALYSIS (RCA)

• Why is RCA Important to Maintenance?
• Understand the Main Function of RCA
• What are the Obstacles of RCA?
• Complex Systems and Interdependencies
• Blaming Individuals Instead of Systems
• Resistance to Organisational Changes
• Overlooking Organisational Factors
• Value Added vs Non-Value Activities

DAY FOUR: FAILURE MANAGEMENT AND ROOT CAUSE ANALYSIS (RCA)

• Understand the RCA Policies
• Assess Current RCA Processes in Place
• Selecting the Appropriate Tools to Conduct RCA
• Integrate RCA into Incident Management
• Combining RCA With Quality Control and Process Improvement
• Create and Include a Corrective Action Plan
• Monitor Key Performance Indicators (KPIs)
• Leadership Support and Commitment

DAY FIVE: PROJECT MANAGEMENT FOR ROOT CAUSE ANALYSIS (RCA)

• Preparations for Developing the RCA Team
• Organisational Structure and Culture
• Establish a Successful RCA Team
• Managing and Motivating the Team
• Use Influence When Proposing Solutions
• Implementing Corrective Action Steps
• Monitor Key Performance Indicators (KPIs)
• Preparing the Final Report and Recommendations