Reliability Center, Inc. 2000Root Cause Analysis: The PROACT ApproachPresented by:Robert J. LatinoReliability Center, Inc.www.reliability.com

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Table of Contents : Reliability Center Inc. Average ROI of Root Cause Analysis. Calculating a Gap PROACT Methodology PROACT Software, version 2

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000RCI IntroductionFounded Allied Chemicals Corporate R & D Reliability Center in 1972Developed The Reliability Approach to Quality and ProductivityR & D focused around Equipment, Process and Human Reliability

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Introduction Average Returns On Investment600 - 1000%

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Average Returns On Investment600 - 1000%Inland SteelE. Chicago, IN3,100% ROIEastman ChemicalCo.Kingsport, TN4,200% ROI LYONDELL-CITGOHouston, TX17,900% ROIROOT CAUSE ANALYSIS: Improving Performance for Bottom Line Results (Latino & Latino, 1999/June, CRC Press, Boca Raton, FL)

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Failure Modes & Effects Analysis Calculate the "Gap"Actual = 275 Million Pounds/YearGap = 115 Million Pounds/YearPotential* = 390 Million Pounds/Year* Note: Potential is top design capacity or high sustained production over a period of time

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Failure Modes & Effects Analysis Determining the "Significant Few"80% of loss 20% of lossRCAPSM - Problem Solving Methods for Continuous ImprovementRoot Cause Analysis

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Two-Track RCA Approach100% CoverageRCA MethodsPSM

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Where do the Events To Analyze Come From?RCIs Modified FMEA ProcessMeridiums Reliability SuiteDEIs SAW (RCM) ProgramCMMS Generated Bad Actor ListsEAP/ERP Generated Bad Actor ListsProblems detected with a predictive maintenance toolsCustomer Complaint ListsSafety Incident ListsQuality Defect ListsRegulatory IncidentsMaintenance Logs

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Introduction PROACT MethodologyPReserve Event DataOrderAnalyzeCommunicate Findings & RecommendationsTracking the Results Failure Modes & Effects AnalysisThe RCA Process

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000PReserving Event Data You Need to ...

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Reliability Center, Inc. 2000PReserving Event Information Five Types of Event DataThe 5 P's

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Ordering the Analysis RCA Project FlowchartDevelop team charter, critical success factors, start/end datesDevelop 5 P's and data collection assignmentsBegin logic tree and assign verifications to team members (reiterate as needed)Develop recommendations and action plansWrite report and make final presentation

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Analyze The 7-Step Process1. Describe the Event2. Describe the Modes3. Hypothesize4. Verify the Hypotheses5. Determine Physical Roots and Verify7. Determine Latent Roots and Verify6. Determine Human Roots and Verify

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Three Levels of CauseFailure Analysis"WitchHunting"RCA

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Communicate Findings & Recommendations RCFA Presentation Agenda

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Tracking for Results As Proaction Increases...Growth & Security Increases

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000PROACT SoftwarePlant Engineering Magazine1998 Gold Award WinnerGeneral & Maintenance SoftwareRoot Cause Analysis System

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Root Cause Analysis System VERSION 3

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000The PROACT SystemPReserving Event DataOrdering the Analysis TeamAnalyzing Event DataCommunicating Findings & RecommendationsTracking For Bottom Line Results

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Reliability Center, Inc. 2000PReserving Event DataThe 5 PsTeam MemberFile Linking

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Reliability Center, Inc. 2000Ordering the Analysis Team Easily Assign MembersTeam PoolQuickly Set Permissions by Right-Clicking

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Analyzing Event DataDrag/Drop Logic TreeLogic Tree IconsPresentation Mode

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Communicating Findings & Recommendations

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Communicating Findings & RecommendationsCustom Report Writer

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Tracking For Bottom Line ResultsChart Wizard

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000PROACT TrainingProblem Solving Methods (PSM) for Business, Industry & Government (1-Day) - For Team MembersRoot Cause Analysis Methods for Principal Analysts (3-Days) - For Team LeadersThe Reliability Performance Process (TRPP) for Managers (1-Day) - For Team SponsorsRoot Cause Analysis Overview for Managers (1-Day) - For Team Sponsorswww.reliability.com

PROACT Software Training (1-Day) - For PROACT Users

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Whats The Organizations Objective?Single-UserVSNetwork (SQL/ORACLE)USAEuropeAsiaLatin AmericaServer

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000PROACT 3.0 Enterprise VersionEstablishes Knowledge Management System for CorporationDevelops World Class Analytical SkillsResults in Drastic Cost Savings and Improved PerformanceEnsures Regulatory ComplianceSignificantly Reduces Cycle Times to Conduct Root Cause AnalysesProduces Quick and Quantum ROIs

Benefits:

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000PROACT 3.0 Enterprise VersionRCA Database Search CapabilityQuality Control Publishing FeatureTeam Member Security OptionsDrag/Drop Logic Tree DevelopmentFile Linking OptionsCustomizable Report WriterImportable Team PoolEnhanced Printing of Logic TreeBuilt-In Presentation ModeFeatures:

Reliability Center, Inc. 2000

Reliability Center, Inc. 2000Where Do We Go From Here?Root Cause Analysis Methods for Principal Analysts (3-Days) - For Team Leaders (A.C.R.)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 SponsorsPROACT Software Training (1-Day) - For PROACT Users

Reliability Center, Inc. 2000