COURSE OUTLINE

The course is very closely aligned to the Continual Improvement paragraph of ISO 55000 which states that when a nonconformity or incident occurs in its assets, the organization SHALL take action to control it; deal with the consequences; review the details; determine the causes; implement corrective actions and review the effectiveness of such corrective actions.

RCA/RCFA with related corrective actions is thus fundamental to any asset improvement program and as such should be entrenched in the organisation’s processes. This not only refers to the RCA/RCFA methodology being used but to the management of all related processes, i.e. record the incidents; trigger and scale the investigation; analyse all relevant data; identify best possible corrective actions; implement these to realise the benefits of it not recurring. The training addresses all the above items to ensure an effective Continual Improvement Process is setup and managed within the organisation.

A further aim of the course is to establish a “preventive or defect elimination culture” within the organisation by moving away from blaming during RCA/RCFA sessions. This is done by using Cause-Mapping as the analysis methodology which is based on a “Scientific Based Evidence Chain of Events”. It builds on detailed analyses and cumulative learning from earlier RCA/RCFA cases and fosters accountability and also assists with FMEA studies.

Workshops are conducted based on typical industry examples, training attendees in the use of the Cause Mapping methodology and guide them in structuring and entrenching the RCA/RCFA process within their organizations.

OUTCOMES

After this training, you will be able to:

  • Understand the important influence of processes and people on the organisation’s performance.

  • Establish the necessary failure recording, analysis, and management of corrective action processes.

  • Use the impact on company goals to trigger and scale RCA/RCFA investigations with related improvement actions.

  • Break down and analyze any problem within the organization by applying the cause and effect (cause mapping) principle.

  • Use the cause map to identify and execute solutions that will avoid recurrence of failures.

  • Understand how to develop and apply a prevention instead of a blame culture during an RCA/RCFA investigation.

WHO SHOULD ATTEND?

  • All personnel involved in process and quality improvements

  • All problem-solving team members and leaders

  • All personnel involved in the production and maintenance disciplines.

 

 

DAY-1

RCA FUNDAMENTALS

  • RCFA Introduction

  • Video – Swiss Cheese Model

  • RCFA Terminology

  • Physical/Human/Latent Failure Elements

  • People & Process influences

  • Risk mitigation

  • Video – Bowtie Risk Evaluation

  • RCFA Methodologies

    • 5 Why

    • Fishbone

    • Fault tree

    • Cause Mapping

  • Video – Fishbone & Five-Why

  • RCA/RCFA Cause Map Fundamentals

  • RCA/RCFA Process

  • RCA/RCFA Triggers & Scale

  • RCA/RCFA Business Impact

  • RCA/RCFA Program Failures

  • RCA/RCFA vs. FMEA/RCM

  • Workshop – Plant Downtime Data & $-Pareto Application

  • Workshop – RCA Triggers & RCA Scale

  • Q & A sessions

 DAY-2

RCA/RCFA IN RELIABILITY IMPROVEMENT

Typical Improvement Elements

  • Asset Hierarchy

  • Asset Criticality

  • Maintenance Content Optimisation (PMO & RCM)

  • Workflow Management

  • Condition Monitoring

  • Proactive Maintenance

  • Spares Management

  • FRACAS

  • RCA/RCFA

  • Defect Elimination

    • Video – Optimum Defect Elimination & Downtime/Delay Recording

    • Workshop – Cause Mapping

    • Q & A session

 

PROGRAM SCHEDULE

09:00 am – 10:05 am (Duration 1 hr 5 min)

10 Minutes Break

 10:15 am – 11:20 am (Duration 1 hr 5 min)

10 Minutes Break

 11:30 am – 12:45 pm (Duration 1 Hr 15 min)

  45 Minutes Lunch & Prayer Break

 01:30 pm – 02:35 pm (Duration 1 Hr 5 Min)

10 Minutes Break

 02:45 pm – 04:00 pm (Duration 1 hr 15 min)

 

 

FEEDBACK SESSION

 What is it that the attendees have learned from the course and would wish to implement in their work place.