Root Cause Analysis (RCA) is a process by which the “root cause” of a failure is determined and subsequently rectified to permanently eliminate the cause, rather than continuing to deal with the symptoms. Although there are many RCA Models, Marshall Institute has standardized RCA around the “DMAIC” model from Six Sigma. By using the DMAIC (Define, Measure, Analyze, Improve, Control) Process, more detail is added to the analysis to create a more comprehensive follow up action plan – detail that is not gathered by less robust RCA processes. This program will walk you through each step of the process using a real case study. This hands-on case study exercise will help you utilize and solidify what you have learned.

This Course Will Help You Answer These Questions

• How do you determine if a situation is a candidate for Root Cause Analysis?
• How do you determine the root cause of the problem?
• Will it cost more resource expenditures to remove the root cause of the problem than it takes to deal with the symptoms?

Look What Root Cause Analysis Has Accomplished for the Following Companies:

• Petroleum Development Organization (Oman) has eliminated a compressor problem costing $1.5M through RCA
• MRC Bearings reduced annual oil consumption by $80,000 through an RCA project
• Harley Davidson eliminated a $21,000 (annually) filter problem and increased equipment uptime by 25%
• Aera Energy, 2-time recipient (2002 & 2004) of the North American Maintenance Excellence (NAME) Award, requires an RCA on all problems over a certain “trigger” value
• Two of Shell’s off-shore assets have eliminated trips (unplanned shutdowns) amounting to a gain of 156,000BOE annually through RCA

• Understand how to use RCA to reduce equipment and system failure
• Understand the different levels of Root Cause Analysis
• Understand and be able to use RCA tools and forms to reduce repair time
• Understand and apply team and facilitation skills
• Understand and apply the selection process to determine RCA candidates
• Understand and apply the DMAIC process

• Maintenance Technicians
• Maintenance Engineers
• Manufacturing Engineers
• Maintenance Supervisors
• Production Supervisors
• Maintenance Managers
• Production Managers
• Operations Lead Personnel
• Maintenance Lead Personnel
• Continuous Improvement Practitioners
• Continuous Improvement Managers
• Those involved in Lean, SixSigma, TPM, TPR
• Anyone involved in root cause problem solving

Introduction to Root Cause Analysis

Definition of RCA
RCA vs RCFA
Achieving Excellence Through RCA

Framework for Root Cause Analysis

Level A: Why-Why Analysis
Level B: Breakthrough
Level C: DMAIC

Root Cause Analysis Tools

Problem Definition
Pareto Chart
Check Sheets
Run & Control Charts
Histograms
Scatter Diagrams
Process Mapping
Brainstorming
Nominal Group Technique
Fishbone Diagrams
5 Why Analysis
Why/Why Tree Diagram
Project Quantification

Team Concepts

RCA Candidate Selection Process

Using the DMAIC Process

Define
Create Team Charter
Project Quantification

Measure
Create Process Map
Collect Data on Failure
Compile Data

Analyze
Create Fishbone Diagram
Conduct 5 Why Analysis/Tree Diagram
Compile Data & Root Cause Theory

Improve
Identify What to Change & What to Change To
Select Intermediate Solutions
Develop an Implementation Plan

Control
Conduct Risk Assessment
Leverage Opportunities
Complete Project Documentation

	Greg Folts Mr. Folts is an experienced manager of continuous improvement having gained his knowledge first-hand directing improvement initiatives for an aerospace bearing supplier, MRC Bearings. These initiatives included responsibility for implementing TPM, 5S, lean production, setup reduction, Six Sigma and ACE initiatives in a 1000 employee, union factory. As TPM Coordinator and Facilitator, Greg developed implementation plans, steering committees, area coordinators, machine standards, TPM procedures, training plans and coordinated... Read More
	Steve Poffenbarger Steve Poffenbarger is a training professional with over twenty years of industrial experience including control, distribution and automation products and systems associated with employment for major equipment manufacturers. Over the years Steve has held various quality control, R&D and field service positions with companies such as Westinghouse, Gould and Telemecanique. His in plant experience has provided him with the understanding of how industrial electrical products are designed and built. Having also worked in the... Read More

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