The RCCA PPT is an excellent training tool to implement into your functional group or business. It basically forces you to peel the onion on a failure as far back until you’ve reached the root cause whereas in some cases it could be several. It incorporates the 5 whys and the problem solving technique.

1. Root Cause Corrective Action Your Instructor: Romains Bos Contain Solve D R C R R

2. Root Cause Corrective Action Your Instructor: Romains Bos

7. Feel like you’re drowning in problems? Cause Analysis & Mistake proofing can rescue you!

8. Don’t Mess With It! YES NO YES YOU IDIOT! NO Will it Blow Up In Your Hands? NO Look The Other Way Anyone Else Knows? You’re DONE! YES YES NO Hide It Can You Blame Someone Else ? NO NO PROBLEM! Yes Is It Working? Did You Mess With It? Traditional Problem Solving

19. Success depends on you. Participate actively!

20. RCCA Cause Analysis Flow Chart Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Mistake Proofing Implement & Follow up DONE Contributing Direct Root

21. Containment and Problem Identification Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Mistake Proofing Implement & Follow up DONE Contributing Direct Root

23. Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Mistake Proofing Implement & Follow up DONE The Event Contributing Direct Root

25. So, you have had an EVENT--

26. First, you react!

33. NCR Response Format Effectivity Date: Objective Evidence Attached: Action Taken to Prevent Recurrence: Impact of all Identified Causes and the Root Cause: Root Cause of Nonconformances: Immediate Corrective Action Taken (Containment Actions): Describe what was accomplished to stop producing nonconforming product, assess damage, contain all effects, and to notify customers (as applicable).

42. Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Mistake Proofing Implement & Follow up DONE Identify Problem Contributing Direct Root

67. No Big Secret! Simple Question Simple Answer Simple Question Simple Question Simple Answer Simple Answer Simple Answer

70. Root Cause Corrective Action Your Instructor: Romains Bos Contain Solve D R C R R

76. Cherry picking will not lead to success! Use the cause chain!

77. The Complete Cause Chain: Event Direct Cause Contr. Cause How many root causes are you allowed? Root Cause

78. How many Root Causes can you have? C C Event Problem #1 Direct. Cause How many root causes are you allowed? Root Cause Problem #2 Direct. Cause Root Cause C C C C C C

80. How many Root Causes can you have? C C Event Cont. Cause One or more, if you have multiple branches Root Cause Cont. Cause Root Cause C C C C C C Direct. Cause Root Cause C C C C

82. Ignorance Silly Workable Times asked “why” Unworkable

87. The process of questioning the answer is continued at least 4 more times (i.e., 5 Why) for each Why . Parts did not respond to H/T Procedures Incorrect Technician Training Temperature Distribution Controller T/C Problem Be sure to keep your questions in line with the original issue. Otherwise, you can stray into unrelated areas and waste time. Material Problem Time/Temp Cycle Temperature Uniformity Quench Delay

89. Once the tree is complete, a detailed review of each of the potential causes can be performed. Compare it with facts gathered to determine if it is a demonstrated contributor. Temperature Distribution Damaged Baffles Burned Out Heater Elements Door Air Leak Deteriorated Insulation Continued fact finding into each potential cause may be required to determine the overall contribution of each item.

90. The next step is to document findings in detail. A discussion of the potential cause and findings should be provided. Temperature Distribution 3.12 Temperature Uniformity 3.1.2.1 Door Air Leak 3.2.1.1.1 Preventative Maintenance Discussion: A worn door seal allowed air leaks that influenced temperature patterns within the furnace work zone. RCA Finding: Preventative maintenance procedures should be revised to include inspection of door seals. 5 Why Matrix Block RCA Discussion Document 3.2.1.1.1

91. When detail discussion of the 5 Why analysis is complete, individual root cause findings can collected and analyzed to identify those with the most impact to the process. 3.2.1.1.1 Preventative Maintenance 3.2.1.1.1 Preventative Maintenance Look for patterns in the findings. Understanding patterns will help when it comes time to develop the Corrective Action Plan. 3.2.1.1.1 Preventative Maintenance Discussion: A worn door seal allowed air leaks that influenced temperature patterns within the furnace work zone. RCA Finding: Preventative maintenance procedures should be revised to include inspection of door seals.

94. The cause chain is your bridge between the event and the solution. Trust it!

103. Remember…we want to break the “Cause Chain.” Preventive C/A Specific C/A Root Cause Contrib. Cause Direct Cause Event

113. Select A Matic Got a problem? Give it a spin! RCCA Lack of Management Support (Not allowed Spin again.) Unknown (Spin again and don’t tell anyone Lack of Discipline (Send employee to obedience school.) Lack of Training (Add unrelated classes to training record.) Lack of System (Make another procedure.) Bad Procedure (Make procedure longer.) Not a Finding ( Recalibrate the auditor.) Lack of Time (Get employee a new watch.)

121. Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Contributing Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Direct Root Mistake Proofing Implement & Follow up DONE Mistake Proofing

122. Consider: Mistake Proofing!

131. Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Contributing Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Direct Root Mistake Proofing Implement & Follow up DONE Implement & Follow Up

135. Who Performs Follow-Up? Who Performs Assessment? When is Assessment Performed? How do you Assess?

136. The team must decide!

141. Did Corrective Actions Work? Follow-up A New Corrective Action? Was C/A Accomplished as Stated? Time to Assess Yes! No!

142. Did Corrective Actions Work? Follow-up Reevaluate cause chain and Corrective Action? Was C/A Accomplished as Stated? Done! Yes! No!

144. Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Contributing Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Direct Root Mistake Proofing Implement & Follow up DONE Complete Final Report

145. Loop Back NO YES! EVENT Form Team Identify Problem Gather & Verify Data Determine Causes Contributing Determine Corrective Actions (Specific & Preventative) Solution Acceptable? Direct Root Mistake Proofing Implement & Follow up DONE Document Follow-up Write final Report Document C/A Document Causes Minutes Team Mtgs Document Team(s)

153. Success depends on you. Participate actively!