Root Cause Analysis - Fourth Edition

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Description

Undesirable outcomes, chronic failure, incidents, and accidents… The cost of such events to corporations is high, generally adding up to tens and hundreds of millions of dollars in "accepted" losses. Why accept these losses? What if you could understand why these errors occur and eliminate chronic events from occurring altogether?

Root Cause Analysis: Improving Performance for Bottom-Line Results shows how to identify, understand, and prevent chronic problems that hinder the attainment of organizational goals using Root Cause Analysis (RCA). In addition, the PROACT software, voted "Product of the Year" by Plant Engineering Magazine, and the steps outlined in this text teach you how to automate the RCA process. Used effectively, the information in Root Cause Analysis will improve the reliability of your plant assets and save your company precious time and money.

Author: Robert, Kenneth and Mark Latino
Published: 2011
Format: Hardback
Pages: 279
Table Of Contents:

Introduction to the PROACT Root Cause Analysis (RCA) Work Process
Mean Time Between Failure (MTBF)
Frequency of Events
Maintenance Cost
Availability
Reliability
Balanced Scorecard
The RCA Work Process

Introduction to the Field of Root Cause Analysis
What is Root Cause Analysis (RCA)?
Why Do Undesirable Outcomes Occur? The 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: The Reliability Performance Process (TRPP)
The Role of Executive Management in RCA
The Role of a RCA Champion (Sponsor)
The Role of the RCA Driver
Setting Financial Expectations: The Reality of the Return
Institutionalizing Root Cause Analysis (RCA) in the System

Failure Classification
RCA as an Approach

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

The PROACT® RCA Methodology
Preserving Event Data
The Error-Change Phenomenon
The 5-Ps Concept
Parts
Position
People
Paper
Paradigms

Ordering the Analysis Team
Novices versus Veterans
The RCA Team

Analyzing the Data: Introducing the PROACT Logic Tree
An Academic Example
Confidence Factors
The Troubleshooting Flow Diagram

Communicating Findings and Recommendations
The Recommendation Acceptance Criteria
Developing the Recommendations
Developing the Report
The 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: The Utilization of The 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
Reviews: Offering advice for identifying, understanding, and preventing chronic problems in business organizations, this book provides instruction on applying "Root Cause Analysis" to minimize losses. Chapters cover the classification of failure, failure modes and effects analysis, reliability, analysis teams, logic trees, communication findings and recommendations, tracking results, and the use of PROACT version 2.0. Case studies illustrate major points. By Book News Inc.

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