Root Cause Analysis: Improving Performance for Bottom-Line Results, Third Edition

There is no easy answer to the question, “What is RCA?” Some will give a general idea of what Root Cause Analysis (RCA) is designed to accomplish, while others will advocate a specific approach. In this third edition of the best-selling Root Cause Analysis: Improving Performance for Bottom-Line Results, acclaimed experts Robert and Kenneth Latino offer a broad look at the various types of approaches to RCA, comparing their pros and cons while supplying practical tools for implementing or improving current RCA initiatives. This edition expands the scope of RCA, taking a holistic approach that includes recent perspectives, opportunity analysis, and RCA’s fit with current initiatives such as Total Quality Management (TQM) and Six Sigma. In addition to a broader perspective, the book presents updated and expanded material including: a chapter devoted to problem-solving/brainstorming; methodology versus software; using the PROACT® approach complimented by the PROACT® Enterprise Version 3.0 software; discussion of the various conflicting definitions of common terms used in RCA; and a focus on measuring ROI. Emphasizing the organizational support necessary for successful RCA efforts, Root Cause Analysis: Improving Performance for Bottom-Line Results, Third Edition demystifies the concepts involved in effective RCA and presents hands-on guidance for program enactment.

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

Review :
Unfortunately, hero-based maintenance, noble as it is, is not the most effective business strategy and points to a reactive corporate culture. The problem solving methods discussed in this book cover much more than how to determine the obvious cause of the problem. This book discusses how to set up a blame free methodology that encourages deeper problem discovery that results in permanent solutions. It stresses that Root Cause Analysis requires a dedicated team coupled with management support and explains ways to communicate the impact so a business case can be made. Best of all it teaches how to create an entire company of proactive problem solvers that will move your operation to the next level of profitability and effectiveness. I am confident that this book will have a profound effect on your problem solving ability.