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Root Cause Analysis - Fourth Edition

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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.

Root Cause Analysis

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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.