INTRODUCTION FOR ROOT CAUSE ANALYSIS FOR MANUFACTURING AND OPERATION PERSONALS
Problems and problem solving activities are a day to day affair in manufacturing. Problems are solved in many ways, some do it technically and some through their Experience. However the main focus should be to eliminate the problem permanently. There should be no re occurrence there after. Is it achieved ? In many situations the same problem re-appears within a few weeks or sometimes within few days. Why this happened ? we always fine a quick answer on human error, forget, lack of skill, did not follow SOP and worst still blame it new operator. Are we sure that this are the root causes. Most of our findings are potential cause and not the root cause. Every problem may have many potential cause but there will a root cause to every one of that. In order to eliminate problems permanently, one should be equipped with tools and techniques that are proven to identify the potentials causes and finally the actual root cause. This program is designed to take the participants through the several process of identifying, establish severity, analysing, finally establish the root cause and then how to use PDCA for permanent corrective action.
COURSE OBJECTIVES
- Provide general overview of problem and the complex nature.
- Understand the 4 components of every problem
- How to determine the severity of problems.
- How to determine when we should do RCA.
- Understand the various tools available RCA
- How to pin point the root cause.
- How to work PDCA to establish good corrective action.
- Move away from reactive culture to proactive culture.
- RCA kaizen cycle.
WHO SHOULD ATTEND
All manufacturing / operation personals – ( managers, engineers, foreman,
supervisors, officers and section heads.
COURSE CONTENT
Module 1 : Autonomy of problems
- What is problem
- Nature of problems
- Complex nature of problems
- The relationship between input and problems
- Effect of problems on PQCDSM
- Seven step ROOT CAUSE ANALYSIS
Analysis mode :
Module 2 : Step 1 – Determine what happened
- Understand the problem ( use 4w +1h )
- Importance of data.
- How to collect data ( check sheet, QA defect, customer feed back )
- Visiting failure scene ( FSI )
Module 3 : Step 2 – conduct preliminary investigation
- Determine what information need to be collected.
- Preparing an investigation checklist
- Collecting visual data ( failure item, photograph )
- The power of observation
Module 4 : Step 3 – perform 4C
- Why data is important
- The power of data ( activity )
- Compile all available data
- Confirm data and incident
- Compare all previous corrective actions
- Conclude for the need for
Module 5 : Step 4 – determine problem severity
- The four components of a problem
- Why failure effect is key for RCA
- Introduction to failure effect severity matrix.
- How to determine problem severity.
Module 6 : Step 5 – analyze the potential causes for root cause
- Developing a problem pareto
- Cause and effect analysis
- Why ? why ? analysis
Module 7 : Step 6 – determine forces that caused the problem
- Are problem destined or created.
- Human in-adherence
- Procedural violations
- Machine malfunctions
- Management inefficiency
- Under par material
- Mechanical component problems
- Electrical component problems
Module 8 : Step 7 – determine the real root cause.
- Common un-investigated solutions
- 4 critical for establishing the root cause.
- Determine the root cause using decision making flow chart
- Achieve group
- Prepare a root cause analysis report.
Corrective action mode
Module 9 : Developing permanent corrective actions.
- Every problem needs two prong corrective actions.
- Developing short term control measures.
- Use TOPS for long term
- 8 step PDCA method for permanent solution
- Develop corrective action format .be
- Be innovative and analytical
- Use matrix diagram for evaluation
- Avoid previous corrective actions
- 5 principles for successful implementation.
- How to measure effectiveness
