Root Cause Analysis (RCA)

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About Course

Root Cause Analysis (RCA) is a structured problem-solving methodology used to identify the underlying causes of failures, defects, and inefficiencies in processes, systems, or equipment.

RCA is a globally recognized approach that empowers teams to move beyond surface-level fixes and implement long term solutions that prevent recurrence.

It aligns with continuous improvement and lean principles and is a critical component of world class quality, safety, and reliability initiatives.

This course is structured around one module and four lessons, providing participants with practical tools and step-by-step guidance to effectively analyze problems, uncover root causes, and apply sustainable corrective actions.

These lessons include:

Module 1 Lesson 1:

  • Introduction To RCA
  • Difference Between: Failure Analysis(FA), Root Cause Analysis(RCA), Root Cause Failure Analysis (RCFA)
  • Definition Of Key Terms: Root Cause, Root Cause Analysis, Failure Mode, Failure
    Pattern, Solution, FMEA, Problem, Change Analysis, Event and Casual Factor Analysis

Module 1 Lesson 2:

  • RCA & TQM
  • Features Of TPM
  • Elements Of TPM
  • Goals Of Performing RCA
  • Benefits Of Performing RCA
  • RCA: A Management Tool
  • RCA Techniques And Method

Module 1 Lesson 3:

  • RCA Implementation Tools,
  • RCA Tools: 5 WHYS,
  • RCA Tools: Ishikawa Diagram,
  • RCA Tools: Fault Tree Analysis,
  • RCA Tools: Pareto Analysis,
  • RCA Tools: FMEA,
  • RCA Tools: Barrier Analysis,
  • RCA Tools: Change Analysis,
  • RCA Tools: Action Plan
  • RCA Tools: Verification Plan

Module 1 Lesson 4: 

  • Root Cause Analysis Application
  • Types Of Root Cause
  • The 3Rs Of Root Cause Analysis
  • The Root Cause Analysis Template
  • Practical Tips For RCA Success
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What Will You Learn?

  • COURSE OVERVIEW:
  • Root Cause Analysis (RCA) is a systematic method for identifying the underlying causes of problems, defects, and failures in processes or equipment. Widely used in maintenance, quality, and operations, RCA aims to prevent recurrence by addressing issues at their source.
  • This practical RCA training program equips participants with the tools and techniques needed to analyze problems effectively, develop long term solutions, and improve organizational performance. Facilitated by experienced professionals, the course blends theory with hands-on case studies to build real world problem solving skills.
  • COURSE LEARNING OBJECTIVES:
  • After this course, participants will be able to:
  • Understand the fundamentals and importance of RCA in operations and maintenance.
  • Link RCA with quality systems such as Total Quality Management (TQM) and TPM.
  • Explore opportunities for continuous learning and development in root cause analysis.
  • Understand legal and ethical considerations in conducting RCA investigations.
  • Develop practical skills in creating RCA templates and communicating findings to stakeholders.
  • Utilize various RCA techniques and tools to analyze data and prioritize causes effectively
  • Identify, investigate, and eliminate root causes using proven RCA methods.
  • Apply tools like the 5 Whys, Fishbone Diagram, and Fault Tree Analysis.
  • Use RCA as a management tool for continuous improvement and decision making.
  • Prevent recurring issues and improve reliability, safety, and process efficiency.

Course Content

INTRODUCTION
Root Cause Analysis (RCA) is a structured problem-solving methodology used to identify the underlying causes of failures, defects, and inefficiencies in processes, systems, or equipment. RCA is a globally recognized approach that empowers teams to move beyond surface-level fixes and implement long-term solutions that prevent recurrence. It aligns with continuous improvement and lean principles and is a critical component of world-class quality, safety, and reliability initiatives.

LESSON 1.0
1.1 Introduction To RCA 1.2 Difference Between: Failure Analysis(FA), Root Cause Analysis(RCA), Root Cause Failure Analysis (RCFA) 1.3 Definition Of Key Terms: Root Cause, Root Cause Analysis, Failure Mode, Failure Pattern, Solution, FMEA, Problem, Change Analysis, Event and Casual Factor Analysis

LESSON 2.0
2.0 RCA & TQM In this lesson, participants will explore the connection between Root Cause Analysis (RCA) and Total Quality Management (TQM), emphasizing how both support continuous improvement and operational excellence. 2.1 Features of TPM The session outlines the key features and elements of Total Productive Maintenance (TPM) and how they align with the goals of performing RCA, such as eliminating recurring problems, improving reliability, and enhancing efficiency. 2.2 Elements of TPM 2.3 Goals of performing RCA - To find out what happened - Why it happened and - What changes need to be made to prevent it from happening again. 2.4 Benefits of performing RCA - Providing Enhanced Utilization Of Available Resources - Avoiding Unnecessary Disruptions - Ensuring Objective Problem Solving - Facilitating Development Of A Comprehensive Set Of Solutions - Predicting Other Problems - Identifying, Assembling, And Integrating Contributory Circumstances - Improving Process Efficiencies Within The Organization 2.5 RCA: A management tool Root Cause Analysis Can Be An Effective Management Tool For Finding The True Or Actual Cause Of Events, Facilitating Corrective Action, And Preventing Their Recurrence. 2.6 RCA techniques and method

LESSON 3.0
3.0 RCA Implementation tools It Can Be Used While Defining The Problem To Determine What Is In Scope And Will Be Considered During The Analysis And What Is Out Of Scope And Will Not Be Considered. It Can Also Be Used When Planning A Solution, To Help The Team Decide What To Include And What To Exclude. 3.1 RCA tools: 5 WHYS The 5 Why Method Is Simply Asking The Question “Why” Enough Times Until You Get Through All The Symptoms Of A Problem And Down To The Root Cause. 3.2 RCA Tools: Ishikawa diagram The Ishikawa Or Fishbone Diagram Is A Useful Tool In Determining The Most Likely Causes (MLCs) Of A Problem. 3.3 RCA tools: Fault Tree Analysis, Fault Tree Analysis (FTA) Is A Method For Root Cause Analysis That Uses Boolean Logic (Using AND, OR, And NOT) To Figure Out The Cause Of Failure. 3.4 RCA tools: Pareto Analysis A Statistical Technique In Decision Making That Is Used For Analysis Of Selected And A Limited Number Of Tasks That Produce Significant Overall Effect. The Premise Is That 80% Of Problems Are Produced By A Few Critical Causes (20%). 3.5 RCA tools: FMEA Failure Modes and Effects Analysis (FMEA) Is A Well-Defined Tool That Can Identify Various Modes Of Failure Within A System Or Process. 3.6 RCA tools: Barrier Analysis Investigation Or Design Method That Involves The Tracing Of Pathways By Which A Target Is Adversely Affected By A Hazard, Including The Identification Of Any Failed Or Missing Countermeasures That Could Or Should Have Prevented The Undesired Effect(s). 3.7 RCA tools: Change Analysis, Looks Systematically For Possible Risk Impacts And Appropriate Risk Management Strategies In Situations Where Change Is Occurring. 3.8 RCA tools: Action Plan Once The Team Has Determined The Root Cause Using Any Combination Of The Tools Listed Above Then They Must Develop The Appropriate Counter-Measures Or Corrective Actions. 3.9 RCA tools: Verification Plan The Team Should Also Determine A Verification (Or Validation) Plan. This Is Used To Provide A Documented Performance Appraisal Of The Counter-Measures Effectiveness.

LESSON 4.0
4.0 Root Cause Analysis Application 4.1 Types of Root cause - Safety-Based RCA - Production-Based RCA - Process-Based RCA 4.2 The 3Rs of Root Cause Analysis - When To Perform A Root Cause Analysis - Recognize - Corrective Actions - Rectify - Replicate 4.3 The Root Cause Analysis Template Performing A Root Cause Analysis Can Be A Great Option And, With The Help Of A Root Cause Analysis Template, The Team Can Create A Repeatable And Effective Problem-Solving Structure. 4.4 Practical tips for RCA success

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