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EES-SIYAKHA CONFERENCE CENTRE |
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Root Cause Analysis (RCA)
Providing a methodology for investigating, categorising and eliminating root causes of incidents whether these are safety, quality, reliability or manufacturing process consequences
Earn 2 CPD Credits (CPD ref. SAAMA00281)
FOR A BROCHURE IN PDF ... [ click here ]
Root Cause Analysis (RCA) is trying to understand why something went wrong. It identifies the basic source or origin of the problem so that recurrence of the problem may be prevented. RCA provides a methodology for investigating, categorising and eliminating root causes of incidents whether these are safety, quality, reliability or manufacturing process consequences.
RCA allows us to explain the what, how and why of the undesirable event. It identifies the basic source or origin of the problem. Every undesirable event happens for a reason. There is a specific succession of events that led to that undesirable event. RCA follows the cause and effect path from the final failure back to its origin. RCA separates facts from hearsay. It does not follow a course of trial and error. When the facts are backed up by evidence and science, and are separated from the fiction, we now have a better understanding as to the real root causes of the problem.
RCA has many applications. However, in industry its most common applications are in maintenance and safety. Many maintenance functions routinely apply RCA to address equipment breakdowns, but with the major focus of organisations on SHEQ RCA is an indispensable tool.
Workshop outcomes
- To give you an understanding of the RCA process
- Knowing how and when to implement RCA in the context of the organisation’s overall reliability improvement strategy.
- Determining how to identify common manufacturing errors and deviations
- Learn how to develop and implement effective Root Cause Analysis Failure Analysis Programme
- Gain insight on how to establish a culture of proactive failure management throughout the organisation
Who should attend?
- Maintenance Technicians
- Maintenance Engineers
- Manufacturing Engineers
- Maintenance/Production Supervisors
- Maintenance/Production Managers
- Operations/Maintenance Lead Personnel
- Continuous Improvement Managers and Practitioners
- Those involved in Lean, Six Sigma, TPM, TPR
- Anyone involved in root cause problem solving
Workshop outline
Day One
Failures and Causes
- Failure definition
- Primary and secondary failures
- The 3 levels of failure causes
- Chronic and sporadic failures
- Practical work
The RCA Process
- Goals of RCA
- Presumptive causes
- Contributing causes
- Root causes
- The RCA process model
Selecting the Problem
- Sources of Problems
- Pareto Analysis
- Practical work
Defining the Problem
- Why define problems?
- When to define a problem
- Criteria for a well defined problem
- Characteristics of a well defined problem
- Practical work
Data Collection
- Why is data collection important?
- Different types of data
- Physical, documentation, and human evidence
- Interviewing
Finding Root Causes
- Brainstorming
- Why Trees?
- Fishbone Analysis
- Practical work
Day Two
Task Analysis
- What is Task Analysis?
- Why do Task Analysis?
- When to do Task Analysis
- Paper and pencil Task Analysis
- Walk Through Task Analysis
- Practical work
Change Analysis
- What is Change Analysis?
- Limitations of Change Analysis
- Procedure for Change Analysis
- Practical work
Barrier Analysis
- What is Barrier Analysis?
- Barrier Analysis concept
- Types of Barriers
- Limitations of barriers
- Practical work
Event and Causal Factor Charting
- What is ECFC?
- Limitations of ECFC
- Procedure for ECFC
- Practical work
Corrective Actions
- Developing corrective actions
- Adaptive and monitoring actions
- How to develop corrective actions
Setting up a RCA Programme
- Employee attitudes
- The roles of the Executive, Champion and
Team Leaders
- The table below shows the feedback of a sample* of delegates who attended this course in 2008/2009
About your facilitator
Eric Maclear is Managing Director of Resource Techniques SA (Pty) Ltd. In Johannesburg, South Africa. He is a highly respected management consultant with more than 25 years experience. For the past 15 years he has been running his own consulting and training company. He is a trained and qualified Industrial Engineer having studied both locally and internationally. He holds a B. Eng degree and has completed a number of Business School Programmes.
Eric has had much experience in Asset & Maintenance Management and has a
particular interest in Reliability-centred Maintenance and Root Causes Failure
Analysis. He has held a number of senior management positions with high profile
international companies. He began his consulting career in 1980 with an Australian based management consultancy where he completed a number of assignments in implementing planned maintenance systems. He later worked for a prominent SA consulting firm consulting and training in the full spectrum of plant operations. During his career as a management consultant he has successfully completed many assignments across a broad spectrum of industries, facilitated many training courses, and was keynote speaker at international conventions. He has also written and published numerous papers on Root Cause Failure Analysis. Eric has facilitated training courses in Southern Africa, USA, UK, China and Middle East. |
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