Transcript Root Cause Analysis: The PROACT™ Approach

Root Cause Analysis:
The PROACT™ Approach
Presented by:
Robert J. Latino
Reliability Center, Inc.
www.reliability.com
Reliability Center, Inc. © 2000
Table of Contents :
• Reliability Center Inc.
• Average ROI of Root Cause Analysis.
• Calculating a Gap
• PROACT Methodology
• PROACT Software, version 2
Reliability Center, Inc. © 2000
RCI
Introduction
• Founded Allied Chemical’s Corporate R
& D Reliability Center in 1972
• Developed “The Reliability Approach to
Quality and Productivity”
• R & D focused around Equipment,
Process and Human Reliability
Reliability Center, Inc. © 2000
Introduction
Average Returns On Investment
600 - 1000%
"In essence, RCA
is FREE!!!"
Reliability Center, Inc. © 2000
Average Returns On Investment
600 - 1000%
ROOT CAUSE ANALYSIS: Improving Performance for Bottom
Line Results (Latino & Latino, 1999/June, CRC Press, Boca
Raton, FL)
Inland Steel
E. Chicago, IN
3,100% ROI
Eastman Chemical Co.
Kingsport, TN
4,200% ROI
LYONDELL-CITGO
Houston, TX
17,900% ROI
Reliability Center, Inc. © 2000
Failure Modes & Effects Analysis
Calculate the "Gap"
Potential* = 390 Million Pounds/Year
Gap = 115 Million Pounds/Year
Actual = 275 Million Pounds/Year
* Note: Potential is top design capacity or high sustained
production over a period of time
Reliability Center, Inc. © 2000
Failure Modes & Effects Analysis
Determining the "Significant Few"
% of Loss
Failure Events
60%
50%
RCA
Root Cause
PSM
40%
for Continuous Improvement
Analysis 30%
20%
10%
0%
80% of loss
- Problem Solving Methods
20% of loss
Reliability Center, Inc. © 2000
Two-Track RCA Approach
RCA
Methods
Events
• Principal Analyst
Required
• Involves All Levels
• Part Time/Full Time
• Root Cause Analysis
• Extremely Disciplined/High
Attention to Detail
Significant Few - 80% of Losses
100% Coverage
Random Many - 20% of Losses
PSM
• Hourly/Supervisory
Level
• Part Time
Reliability Center, Inc. © 2000
• Problem Solving Skills
• Less Attention to Detail
Where do the Events To Analyze Come From?
•RCI’s Modified FMEA Process
•Meridium’s Reliability Suite
•DEI’s SAW (RCM) Program
•CMMS Generated Bad Actor Lists
•EAP/ERP Generated Bad Actor Lists
•Problems detected with a predictive maintenance tools
•Customer Complaint Lists
•Safety Incident Lists
•Quality Defect Lists
•Regulatory Incidents
•Maintenance Logs
Reliability Center, Inc. © 2000
Introduction
PROACT™ Methodology
Failure Modes & Effects Analysis
The RCA Process
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PReserve Event Data
Order
Analyze
Communicate Findings & Recommendations
Tracking the Results
Reliability Center, Inc. © 2000
PReserving Event Data You Need to ...
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PReserving Event Information
Five Types of Event Data
Parts
Position
People
Paradigms
Paper
Reliability Center, Inc. © 2000
The 5 P's™
Ordering the Analysis
RCA Project Flowchart
Develop team charter, critical
success factors, start/end
dates
Develop 5 P's™ and data
collection assignments
Begin logic tree and assign
verifications to team
members (reiterate as
needed)
Develop recommendations
and action plans
Reliability Center, Inc. © 2000
Write report and make final
presentation
Analyze
The 7-Step Process
1. Describe the Event
2. Describe the Modes
3. Hypothesize
4. Verify the Hypotheses
5. Determine Physical Roots
and Verify
6. Determine Human Roots
and Verify
7. Determine Latent Roots
and Verify
Reliability Center, Inc. © 2000
Three Levels of Cause
This is where
most asset
management
programs stop!
Failure
Analysis
Physical Roots
"Witch
Hunting"
Human Roots
RCA
Latent Roots
Component Causes
Inappropriate Human Intervention
Deficiencies in Management Systems
Reliability Center, Inc. © 2000
Communicate Findings & Recommendations
RCFA Presentation Agenda
• Review of RCI's RCA Process
• Summary of Event
• Description of Event Mechanism
• Logic Tree Review
• Review of Root Cause Action Matrix
• Recognition of Participants Involved
• Question & Answer Sessions
• Commitment to Action Plan
Reliability Center, Inc. © 2000
Tracking for Results
As Proaction Increases...
Production Increases
Growth & Security
Increases
Reliability Center, Inc. © 2000
Profits Increases
Root Cause Analysis System
PROACT® Software
Plant Engineering Magazine
1998 Gold Award Winner
General & Maintenance Software
Reliability Center, Inc. © 2000
Root Cause Analysis System
VERSION 3
Reliability Center, Inc. © 2000
®
The PROACT System
• PReserving Event Data
• Ordering the Analysis
Team
• Analyzing Event Data
• Communicating
Findings &
Recommendations
• Tracking For Bottom
Line Results
Reliability Center, Inc. © 2000
PReserving Event Data
The 5 P’s
Team
Member
File
Linking
Reliability Center, Inc. © 2000
Ordering the Analysis Team
Easily
Assign
Members
Team Pool
Quickly Set
Permissions
by RightClicking
Reliability Center, Inc. © 2000
Analyzing Event Data
Drag/Drop
Logic Tree
Logic Tree
Icons
Presentation
Mode
Reliability Center, Inc. © 2000
Communicating Findings &
Recommendations
Table of Contents
I. Executive Summary
• Description of Failure Event
• Description of Failure
Mechanism
• Overview of PROACT™
methodology
• Root Cause Action Matrix
II. Detailed/Study Section
• Detailed Recommendations
III. Appendices
•Recognition of Participant Involved
Reliability Center, Inc. © 2000
Additional (Optional)
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5 P’s Data Collection Forms
Team Member Data
Team Charter
Team CSF’s
Team Start/End Dates
Verification Log
Logic Tree
Communicating Findings &
Recommendations
Custom Report
Writer
Reliability Center, Inc. © 2000
Tracking For Bottom Line
Results
Chart Wizard
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®
PROACT Training
PROACT® Software Training
Day) - For PROACT® Users
(1-
The Reliability Performance Process
(TRPP©) for Managers (1-Day) - For
Team Sponsors
Root Cause Analysis Overview for
Managers (1-Day) - For Team
Sponsors
Root Cause Analysis Methods for
Principal Analysts (3-Days) - For
Team Leaders
Problem Solving Methods (PSM) for
Business, Industry & Government
(1-Day) - For Team Members
www.reliability.com
Reliability Center, Inc. © 2000
What’s The Organization’s Objective?
Asia
Enterpris
e
Version
Desktop
Version
Latin America
VS Enterpris
e
Version
Europe
Server
Enterpris
e
Version
USA
Single-User
Reliability Center, Inc. © 2000
Enterpris
e
Version
Network (SQL/ORACLE)
®
PROACT 3.0 Enterprise Version
Benefits:
• Establishes Knowledge Management System for
Corporation
• Develops World Class Analytical Skills
• Results in Drastic Cost Savings and Improved
Performance
• Ensures Regulatory Compliance
• Significantly Reduces Cycle Times to
Conduct Root Cause Analyses
• Produces Quick and Quantum ROI’s
Reliability Center, Inc. © 2000
PROACT® 3.0 Enterprise Version
Features:
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•
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•
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•
•
•
RCA Database Search Capability
Quality Control Publishing Feature
Team Member Security Options
Drag/Drop Logic Tree Development
File Linking Options
Customizable Report Writer
Importable Team Pool
Enhanced Printing of Logic Tree
Built-In Presentation Mode
Reliability Center, Inc. © 2000
Root Cause Analysis Methods for
Principal Analysts (3-Days) - For
Team Leaders (A.C.R.)
PROACT® Software Training
Day) - For PROACT® Users
(1-
Where Do
We Go
From
Here?
Problem Solving Methods (PSM) for
Business, Industry & Government
(1-Day) - For Team Members (M.R.P.)
The Reliability Performance Process
(TRPP©) for managers (1-Day) - For
Team Sponsors
Reliability Center, Inc. © 2000