Root Cause Analysis
Overview
Fixing symptoms lets problems come back; finding root causes stops them. This course teaches a structured approach to root cause analysis: defining problems precisely, collecting evidence, applying proven tools and putting in place corrective actions that last.
Who should attend
Quality, operations, maintenance, HSE and engineering staff, supervisors and anyone who investigates recurring problems.
Training methodology
Interactive presentations, practical exercises, case studies, group discussions, role-plays where relevant, and a personal action plan that participants apply in their own work.
Objectives
By the end of this course, participants will be able to:
- Define problems clearly and contain their effects
- Collect and analyse data about problems
- Apply 5 Whys, fishbone and fault tree analysis
- Verify root causes with evidence
- Implement and check corrective and preventive actions
Course outline
Day 1Problem Solving Foundations
- Symptoms versus root causes
- Structured problem solving approaches
- Defining the problem: what, where, when, how big
- Containment actions
- Forming the investigation team
- Case study discussion
Day 2Data and Evidence
- Check sheets and data collection
- Pareto analysis
- Run charts and trends
- Stratification
- Process mapping to locate problems
- Exercise: analyse defect data
Day 3Root Cause Tools
- The 5 Whys
- Fishbone (Ishikawa) diagrams
- Is/is-not analysis
- Fault tree analysis
- Change analysis
- Workshop: apply the tools to a real problem
Day 4Verifying Causes
- Testing hypotheses
- Human factors and systemic causes
- Avoiding blame
- Using experiments and trials
- Documenting findings
- Exercise: verify a root cause
Day 5Corrective Action
- Selecting effective solutions
- Error-proofing
- Action plans and ownership
- Verifying effectiveness
- 8D reports
- Building a problem-solving culture
