Root Cause Analysis: Improving Performance for Bottom Line Results

Abstract

Introduction to the PROACT Root Cause Analysis (RCA) Work Process Mean Time Between Failure (MTBF) Frequency of Events Maintenance Cost Availability Reliability Balanced Scorecard RCA Work Process Introduction to the Field of Root Cause Analysis What is Root Cause Analysis (RCA)? Why Do Undesirable Outcomes Occur? Big Picture Are All RCA Methodologies Created Equal? Attempting to Standardize RCA -- Is This Good For the Industry? What is Not Root Cause Analysis? How to Compare Different RCA Methodologies When Researching Them What Are the Primary Differences Between Six Sigma and RCA? Obstacles to Learning from Things That Go Wrong Creating the Environment for RCA to Succeed: Reliability Performance Process (TRPP) Role of Executive Management in RCA Role of a RCA Champion (Sponsor) Role of the RCA Driver Setting Financial Expectations: Reality of the Return Institutionalizing Root Cause Analysis (RCA) in the System Failure Classification RCA as an Opportunity Analysis: The Manual Approach Step 1: Perform Preparatory Work Define the System to Analyze Define Undesirable Event Draw Block Diagram (Use the Contact Principle) Describe the Function of Each Block Calculate the Gap Develop Preliminary Interview Sheets and Schedule Step 2: Collect the Data Step 3: Summarize and Encode Data Step 4: Calculate Loss Step 5: Determine the Significant Few Step 6: Validate Results Step 7: Issue a Report Asset Performance Management Systems (APMS): Automating the Opportunity Analysis Process Determining Our Event Data Needs Establish a Workflow to Collect the Data Employ a Comprehensive Data Collection System Analyze the Digital Data PROACT(R) RCA Methodology Preserving Event Data Error-Change Phenomenon 5-Ps Concept Parts Position People Paper Paradigms Ordering the Analysis Team Novices versus Veterans RCA Team Analyzing the Data: Introducing the PROACT Logic Tree An Academic Example Confidence Factors Troubleshooting Flow Diagram Communicating Findings and Recommendations Recommendation Acceptance Criteria Developing the Recommendations Developing the Report Final Presentation Tracking for Bottom-Line Results Getting Proactive Work Orders Accomplished in a Reactive Environment Sliding the Proactive Work Scale Developing Tracking Metrics Exploiting Successes Creating a Critical Mass Recognizing the Life Cycle Effects of RCA on the Organization Conclusion Automating Root Cause Analysis: Utilization of PROACT Enterprise Version 3.0+ Customizing PROACT For Our Facility Setting Up a New Analysis in the New PROACT FMEA and OA Module Setting Up a New Analysis in the New PROACT RCA Module Automating the Preservation of Event Data Automating the Analysis Team Structure Automating the Root Cause Analysis -- Logic Tree Development Automating the RCA Report Writing Automating Tracking Metrics Case Histories Case History #1: ISPAT Inland, Inc. East Chicago, IN Case History #2: Eastman Chemical Company Kingsport, TN Case History #3: LYONDELL-CITGO Refining Houston, TX Case History #4: Eastman Chemical Company World Headquarters Kingsport, TN Case History #5: Southern Companies Alabama Power Company Parrish, AL Case History #6: Weyerhauser Company Valliant, OK Index

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