Cairo

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Course Description:

Even with the best quality systems and training, problems can happen. Root cause analysis (RCA) describes a wide range of approaches, tools, and techniques used to uncover causes of problems. For engineers, this could be applied to failure analysis in engineering and maintenance, quality control problems, safety performance, and computer systems or software analysis. The goal of RCA is to identify the origin of a problem using a systematic approach and determine:

1. What happened
2. Why it happened
3. How to reduce the likelihood that it happens again
4. How to launch a solution implementation plan

This Five Days course provides a collaborative and dynamic learning environment that affords the participant the ability to perform RCA on real-world problems and overlay solutions to the problems. Each RCA tool is presented in an easy-to-follow structure: a general description of the tool, its purpose and typical applications, the procedure when using it, an example of its use, a checklist to help you make sure it is applied properly, and different forms and templates.

The examples used can be tailored to many different industries and markets, including manufacturing, robotics, bioengineering, energy, and pressure technology. The layout of this course has been designed to help speed participants’ learning through short videos depicting well-known scenarios for analysis in class.

Why Choose this Training Course?

This Root Cause Analysis training course will enable delegates to remain abreast of the latest researched trends, techniques and strategies to improve the condition and performance of their operational process. This hands-on intervention will equip you with the necessary basic knowledge and skills to optimize the function, daily running, and maintenance of the five main aspects of the process.

Delegates will be exposed to and learn the core competencies required for successful problem solving and solution implementation of an effective operations process against the background of the current global economic downturn. They will complete several in-course assignments, which will enhance their problem solving skills and which will serve as an action plan for improvement. Setting the correct priorities and doing the right thing, makes all the difference to your performance.

This Root Cause Analysis training course will highlight:

• Terminologies - 112 Tools and Techniques for RCFA
• A modern holistic approach to understanding the operational process
• Process Maturity Indexing, Planning and Protocols
• Exact performance measurement and performance management modeling
• More than one hundred “Human Factors” as a Source of Error

By the end of this Root Cause Analysis training course, participants will:

• Explain the concept of root cause analysis
• Describe how to use tools for problem cause brainstorming
• Ask the right questions; establish triggers that drive you to the RCA process
• Gain a broad understanding and appreciation of the core functional aspects of how to perform an effective Root Cause and Failure Analysis
• Be able to review the six standard maintenance improvement tactics and their selection technique to ensure reliable process plant & equipment
• Learn how to develop a comprehensive operational process resource and support system analysis
• Understand the principles of an operational audit, develop your own process standard
• Gain insight and understanding into the unique leadership and motivation principles required for technical process operation and management
• Develop strategies for problem cause data collection and analysis
• Deploy tools for root cause identification and elimination
• Perform a cost-benefit analysis
• Practice ways of implementation solutions

Who should attend?
This course is intended for engineers and technical professionals involved in flow of complex processes, materials and equipment, or those who serve in a project or product management function.

This training course is suitable to a wide range of professionals but will greatly benefit:

• Engineering and Technical Managers and Supervisors from any industry
• Maintenance Planners and Coordinators
• Operations and Manufacturing Managers and Supervisors
• Foremen and Team leaders
• Plant Engineers and Process System Managers
• Section Engineers and Planners

Course Outline:

Day One: RCA versus RCFA – Review of Principles

• Overview of Root Cause Analysis Concepts and Practices
• Introduction to Root Cause Analysis (RCA)
• The need and the practice
• Problem identification and definition of problems
• Practical Problem Solving
• Defining a Problem
• Strategies to Solve Problems
• Understanding Causes and Its Levels
• Finding Root Causes
• Eliminating Root Causes
• Proactive Problem Solving
• Case Studies & Hands-on Activity
• Defining your Operational Process
• Terminologies in current use: Integration, Agility, Deviation from Standard
• What is World Class Operations?
• Three knowledge types
• 20 Baseline aspects to consider with RCA as Prime Causes
• Generic Performance Measurement Model of a complex issue – 6 levels
• Single Task performance measurement
• The 10 point Planning Standard and the role of the Planning Department

Day Two: Basic Cause / Effect Dynamics Tools

• Variability Analysis of Causes
• Application of effective Variability Analysis in order to rate and classify Causes
• Selecting the Optimum maintenance tactic distribution
• Run To Failure (RTF)
• Condition Based Maintenance (CBM)
• Time Based Maintenance (TBM)
• Skills Level Upgrade (SLU)
• Design Out Maintenance (DOM)
• Process Maturity Indexing

Day Three: Advanced Cause / Effect Analysis

• A range of simple Cause / Effect relationships
• Seven generic relationships between two variables
• More complex modelling techniques
• A “Blueprint” for effective operational practice
• Leadership Development and Motivation of  Operations employees
• Maintenance/Operations Process Standards based on regular audits with variable frequencies
• Principles of Information Management
• Definition; Difficulty and Commitment combined to assess Probability of Success

Day Four: Problem Solving in the Operations Environment

• Problem Solving Techniques and application
• Tools for Problem Cause Data Collection
• Problem Cause Data Collection
• Taking Advantage of Samplings
• Steps in Using Samplings
• Taking Advantage of SurveysUsing Check Sheets
• Problem Cause Data Collection Checklist
• Case Studies & Hands-on Activity
• Risk identification, assessment and control
• IERIC-PDI Technique
• RCM – 7 key questions
• Consequence of Functional Failure
• 8 “D’s” and ALARP
• Exercises and Facilitation

Day Five: Scenario Analysis and Action Plan Development

• Theory of Inventive Problem Solving

• Tools for Solution Implementation
• Overview of Solution Implementation
• Organizing the Implementation
• Developing an Implementation Plan
• Using Tree Diagrams
• Creating Change Acceptance
• The Purpose and Application of Force-Field Analysis
• Case Study & Hands-on Activity

• Selecting the Right Tool
• What to Watch for When Using Tools and Techniques
• Selecting the Right Tool

• Commercial programs: Pro’s and Con’s
• Addressing delegate problems
• Understanding the complexity - Putting it all together
• Assessment Assignment and program evaluation
• Case Study & Hands-on Activity
• Example Cases and Practice