Root Cause Failure Advanced Analysis

Introduction

The highly interactive Root Cause Failure Analysis course delivers a modern approach to problem solving in maintenance management. The course depends on some of the most recent research in the field. Participants will be enabled to improve the performance of their operation with practical, down-to-earth techniques that are based on first principles.

The following aspects will be discussed:

 Logistics of Continuous Performance Improvement.
 Decision Logic and Operational Knowledge Types.
 Maturity Indexing.
 Relationship Development and Analysis.
 Strategic Focus.
 Complexity; Risk; and Variability Models.

Objectives

Applying the concepts taught in this course, participants will be able to:

 Build up and implement a sustainable world class maintenance strategy.
 Perform a systematic Root Cause Failure Analysis.
 Develop an improved comprehending of numerous maintenance environment variables, and of the relationships between them.
 Comprehend, audit and optimize your maintenance process.
 Comprehend the use and application of generic problem-solving techniques.
 Cascade the principles and benefits of the course to other employees.

Course Outline

Day 1

Problem Solving – Basic Principles

 Problem Identification Session.
 Terminology of RCFA.
 Decision Logic.
 Three Knowledge Types.
 Maintenance Maturity Indexing.
 Six Level Generic Performance Standard.
 Continuous Improvement.
 Exercises.

Day 2

Sustainable Maintenance Performance Improvement 1

 Introduction to Modern Maintenance Practice.
 The SQC Performance Model.
 Reverse Risk Analysis.
 Maintenance /Operations Objectives and Resource Analysis.
 Complexity; Risk; and Variability Models.
 The Maintenance Cost Ratio.
 Solving of Delegate Problems.
 Exercises.

Day 3

Sustainable Maintenance Performance Improvement 2

 Cross Referencing Operational Variables (Group Exercise)
 “Your Maintenance Costs are too High!”
 Sigma Sets: The Absolute Decision Standard
 Data / Knowledge Base
 Accuracy and Availability of Data / Cost relationship
 The Four critical stages of Data Maturity
 Logical Critical Thinking vs. Creative Lateral Divergent Thinking
 Case Studies: Analysis and Exercises.

Day 4

Action Plan Development

 Introduction to TRIZ Methodology.
 Review of Most Suitable Techniques.
 Development of an “Instant Approach” to Problem Solving.
 Application of “Standard Questions”.
 Individual Delegate Requirements.
 Commercial Programs.
 Logistical Requirements for Practical RCFA implementation.
 RCFA Exercises (Analysis of Client Company Specific Problems).

Day 5

Root Cause Analysis

 Maintenance Strategy Development and Implementation.
 Standard Pitfalls for Maintenance Improvement Initiatives.
 Generic Problem-Solving Techniques.
 Logical Problem-Solving Techniques.
 Creative Problem-Solving Techniques.
 Other Problem-Solving Techniques.
 A Systematic Root Cause Failure Analysis Methodology.
 Exercises.