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7/27/2019 RCFA Steps.pdf
http://slidepdf.com/reader/full/rcfa-stepspdf 1/9
Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence
RSARSA20042004
Building RCFA As Part Of A
Structured System
Building RCFA As Part Of ABuilding RCFA As Part Of A
Structured SystemStructured System
Module 7
Module 7Module 7
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence
RSARSA20042004
STEP 1 : EDUCATE ALL PEOPLE ON RCFA ITSELFSTEP 1 : EDUCATE ALL PEOPLE ON RCFA ITSELF
•• Start by educate our maintenance andStart by educate our maintenance and
technical people on RCFAtechnical people on RCFA
HOW TO MAKE RCFA AS PART OF OUR SYSTEM
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
•• Management to set expectations as toManagement to set expectations as to
why their people are trained on RCFAwhy their people are trained on RCFA
••
Conduct management presentation andConduct management presentation andoverview on the basics of RCFA andoverview on the basics of RCFA and
when it should be appliedwhen it should be applied
Root-cause-failure-analysis shouldn't
be over -applied. Abide by the 80-20 rule:
20 percent of problems cause 80 % of
losses. For this, set up a spreadsheetdetailing failures encountered and the
total annual losses associated w/ each.
rank those problems from largest to
smallest annual loss.
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence
RSARSA20042004
STEP 2 : ANALYZE FAILURE MODES TO UNDERGO RCFASTEP 2 : ANALYZE FAILURE MODES TO UNDERGO RCFA
HOW TO MAKE RCFA AS PART OF OUR SYSTEM
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
•• Assign someone to summarize most common and frequent failuresAssign someone to summarize most common and frequent failures
encountered and rank its severity according to its consequenceencountered and rank its severity according to its consequences & costs & cost
•• This is important so as to understandThis is important so as to understand w/cw/c failures will undergo a thoroughfailures will undergo a thorough
Root Cause Failure AnalysisRoot Cause Failure Analysis•• Once the failure modes had beenOnce the failure modes had been
summarized, prioritize high risksummarized, prioritize high risk
failures and thosefailures and those w/cw/c are chronicare chronic
in naturein nature
•• Assign a common RCFA Facilitator Assign a common RCFA Facilitator
and RCFA third party consultant toand RCFA third party consultant to
guide in the initial process of theguide in the initial process of the
RCFA AnalysisRCFA Analysis
•• It is also vital and important toIt is also vital and important to
collect as much data as possiblecollect as much data as possible
regarding the failure for later regarding the failure for later veriveri--
ficationfication of every single hypothesisof every single hypothesis
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence
RSARSA20042004
STEP 3 : CONDUCT THE RCFA ANALYSISSTEP 3 : CONDUCT THE RCFA ANALYSIS
HOW TO MAKE RCFA AS PART OF OUR SYSTEM
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
•• Once the teams had been identified, allowOnce the teams had been identified, allow
them to proceed with the RCFA Analysisthem to proceed with the RCFA Analysis
and determine the Physical, Human andand determine the Physical, Human and
the Latent Cause of the problemthe Latent Cause of the problem
• Analysis processes that stop at the iden-
tification of physical root causes or to thecomponent level always lack depth. Ana-
lyses that focus on people that make bad
decisions are often called “witch hunting”
expeditions. True Root Cause Analysis
will seek to understand why good people
make bad decisions. Why did the personwho made the decision think it was the
right thing to do at the time?
• All RCFA efforts must steer away from
blaming people in the first place and thismust be clear to all people
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence RSARSA20042004
STEP 4 : RECOMMENDATION OF THE IMPROVEMENT PLANSTEP 4 : RECOMMENDATION OF THE IMPROVEMENT PLAN
HOW TO MAKE RCFA AS PART OF OUR SYSTEM
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
• Management commitment should be clear
at the beginning of any RCFA initiative.
teams will lost motivation and enthusiasm
if their recommendations will fall on deaf
ears. Management should review and have
the recommendations approved by the teamwho performed the analysis
• When performing true RCA, getting to the
causes is the easy part, getting somethingdone to eliminate the causes is a whole
different story.
• The most important thing that people must understand is that it does not
matter who did something, what matters is why. If we do not address theWHY a failure is likely to recur. Therefore, if we have verified beyond a
doubt that a latent root exists, then it is a fact. All facts must be addressed
with recommendations.
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence RSARSA20042004
STEP 5 : IMPLEMENTATION OF THE IMPROVEMENT PLANSTEP 5 : IMPLEMENTATION OF THE IMPROVEMENT PLAN
HOW TO MAKE RCFA AS PART OF OUR SYSTEM
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
•• Once the recommendation had been approved plan for theOnce the recommendation had been approved plan for the implementaimplementa--
tiontion of the improvement and countermeasureof the improvement and countermeasure
•• Countermeasure should be two folds, toCountermeasure should be two folds, to
address the Physical roots and both theaddress the Physical roots and both the
Human and Latent Cause of the problemHuman and Latent Cause of the problem
•• Management should understand that unlessManagement should understand that unless
the problems would resurface unless latentthe problems would resurface unless latent
cause of the problem is being addressed.cause of the problem is being addressed.
We must understand that blaming oneWe must understand that blaming one anoano--
ther ther have no room in the RCFA Analysis,have no room in the RCFA Analysis,
what is important is the how & why and notwhat is important is the how & why and not
the who caused the problemthe who caused the problem
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence RSARSA20042004
STEP 6 : TRACK RESULT & MEASURE KEY INDICATORS ON RCFASTEP 6 : TRACK RESULT & MEASURE KEY INDICATORS ON RCFA
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
• ROI is only one measure of effectiveness. However, our Root Cause
Analysis efforts should be further measured as to how they contribute
to the Key Performance Indicators (KPI’s) of the corporation. It is vital
to demonstrate this linkage as it will make the attainment of these goals
dependent on the task of Root Cause Analysis. This further helps to
justify the existence of the Root Cause Analysis effort.
• Measurement will allow us to learn from the things that go wrong and
focus our efforts on improving it. We are what we measure and if wemeasure what is important then our efforts will definitely be rewarded.
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence RSARSA20042004
STEP 7 : SHARE RCFA LESSONS LEARNED & CELEBRATE SUCCESSSTEP 7 : SHARE RCFA LESSONS LEARNED & CELEBRATE SUCCESS
HOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEMHOW TO MAKE RCFA AS PART OF OUR SYSTEM
• The greatest benefit any corporation
can get from their Root Cause Analysisefforts is to raise the knowledge, skill
and awareness of their employees to
issues identified in a RCFA. This is
because we do not want other peopleto make the same triggering
• People who performed well would
want to be recognized. Its Human
Nature. Providing inexpensive and
simple recognition will provide
both benefits to the team and the
company, remember that the com-pany benefited from the improve-
ments done by the RCFA team
7/27/2019 RCFA Steps.pdf
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Rolly Angeles
ROOTCAUSE FAILURE ANALYSIS
M aintenance Excel l ence RSARSA20042004
ACKNOWLEDGMENTACKNOWLEDGMENT
This is to thank the following people that have continuously provided meknowledge and inspiration in driving my passion on reliability & maintenance . . .This is to thank the following people that have continuously provided meknowledge and inspiration in driving my passion on reliability & maintenance . . .
RCFA Consultants and RooticiansRCFA Consultants andRCFA Consultants and RooticiansRooticiansBob Nelms of Failsafe Network, Vee Narayan author of Risk Analysis, Dr.
William Corcoran – Saving Lives, Robert Latino of Reliability Center Inc.,
Terry Herrmann, Michael Mulligan
Bob Nelms of Failsafe Network, Vee Narayan author of Risk AnalysBob Nelms of Failsafe Network, Vee Narayan author of Risk Analysis, Dr.is, Dr.William CorcoranWilliam Corcoran – – Saving Lives, Robert Latino of Reliability Center Inc.,Saving Lives, Robert Latino of Reliability Center Inc.,
Terry Herrmann, Michael MulliganTerry Herrmann, Michael Mulligan
My Friends from ReliabilityMy Friends from ReliabilityMy Friends from Reliability
And most of all to our dear God Almighty for providingme this opportunity to share this brief presentation . . .
And May God Bless Us All
And most of all to our dear God Almighty for providingAnd most of all to our dear God Almighty for providingme this opportunity to share this brief presentation . . .me this opportunity to share this brief presentation . . .
And May God Bless Us AllAnd May God Bless Us All
Terrence O Hanlon, Steve Turner of PM Optimization, Daryl Mather , author of Maintenance Scorecards, Sam Pickens, Bryan Weir CMMS Consultant , Joe
Peterson – Maintenance Editor, Rui Assis Weibull Specialist, Dave Thompson
Terrence O Hanlon, Steve Turner of PM Optimization, DarylTerrence O Hanlon, Steve Turner of PM Optimization, Daryl Mather Mather , author of , author of
Maintenance Scorecards, Sam Pickens, Bryan Weir CMMS ConsultanMaintenance Scorecards, Sam Pickens, Bryan Weir CMMS Consultant , Joet , Joe
PetersonPeterson – – Maintenance Editor,Maintenance Editor, RuiRui AssisAssis WeibullWeibull Specialist, Dave ThompsonSpecialist, Dave Thompson
MaramingMaraming SalamatSalamat Po !Po !