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    Rca Sop

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    Shiva Prakasam Perneti
    The document provides guidelines for conducting root cause analysis of equipment failures and issues at a pig iron plant. It outlines the scope, responsibilities, procedures, timelines, and documentation process for root cause analyses. Root causes must be analyzed for stops over 30 minutes, repetitive failures, major breakdowns, and environmental incidents. Analyses should be completed within 5-10 days and involve operators, area managers, and heads to identify causes and corrective actions. Effectiveness is evaluated based on recurrence of issues.

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    Rca Sop

    Uploaded by

    Shiva Prakasam Perneti
    231 views4 pages
    The document provides guidelines for conducting root cause analysis of equipment failures and issues at a pig iron plant. It outlines the scope, responsibilities, procedures, timelines, and documentation process for root cause analyses. Root causes must be analyzed for stops over 30 minutes, repetitive failures, major breakdowns, and environmental incidents. Analyses should be completed within 5-10 days and involve operators, area managers, and heads to identify causes and corrective actions. Effectiveness is evaluated based on recurrence of issues.

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    RCA SOP

    Original Title

    RCA SOP

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    The document provides guidelines for conducting root cause analysis of equipment failures and issues at a pig iron plant. It outlines the scope, responsibilities, procedures, timelines, and documentation process for root cause analyses. Root causes must be analyzed for stops over 30 minutes, repetitive failures, major breakdowns, and environmental incidents. Analyses should be completed within 5-10 days and involve operators, area managers, and heads to identify causes and corrective actions. Effectiveness is evaluated based on recurrence of issues.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    231 views4 pages

    Rca Sop

    Uploaded by

    Shiva Prakasam Perneti
    The document provides guidelines for conducting root cause analysis of equipment failures and issues at a pig iron plant. It outlines the scope, responsibilities, procedures, timelines, and documentation process for root cause analyses. Root causes must be analyzed for stops over 30 minutes, repetitive failures, major breakdowns, and environmental incidents. Analyses should be completed within 5-10 days and involve operators, area managers, and heads to identify causes and corrective actions. Effectiveness is evaluated based on recurrence of issues.

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    You are on page 1of 4

    PIG IRON DIVISION Doc No: WI/MAINT/

    Doc Title: RCA Guidelines


    E,M &I Departmental Page No: 1 of 4
    Manual Revision No: 10

    ACTIVITY: Guidelines for Root Cause Analysis


    ___________________________________________________________________________________

    Objective :- To have a systematic procedure and guidelines for the Root cause failure
    analysis of plant equipments, process, quality, safety & Environment problems and Monitoring of its
    Corrective and preventive actions. And controlling of the documents related to it.

     Scope :- Blast Furnace & Accessories


     Ref. :- Asset Optimization Guideline of Vedanta
     Responsibility :- All Section Head - Maintenance.
    All Maintenance Staff

    1. TASK PROCEDURES

    Root Cause Failure Analysis Guidelines:

    REVIEWED AND APPROVED BY ISSUED BY DATE

    GM. SECTION HEAD 2115/084/20154


    PIG IRON DIVISION Doc No: WI/MAINT/
    Doc Title: RCA Guidelines
    E,M &I Departmental Page No: 2 of 4
    Manual Revision No: 10

    REVIEWED AND APPROVED BY ISSUED BY DATE

    GM. SECTION HEAD 2115/084/20154


    PIG IRON DIVISION Doc No: WI/MAINT/
    Doc Title: RCA Guidelines
    E,M &I Departmental Page No: 3 of 4
    Manual Revision No: 10

    RCFA to be done for all breakdowns leading to production loss as per below given details

     Plant stoppage for more than 30 min


     Repetitive equipment Failure greater or equal to 2 times in a month or 24 times in a
    year quarter but not necessary resulting in production loss.
     Major break downs of critical equipments
     Environment related breakdowns
     Hot Metal spillage
     Break down of pollution control equipments.
     Gas leakages
     Hazardous waste spillages.
     Major Oil Spillages

    Effectiveness of RCA
    To declare a RCA is effective below is the criteria
    No of Failures occurring in a No of Months action to be
    month or Quarter observed
    1 in a month 3 Declare as effective
    2 in a month 4 Declare as effective
    1 in a Quarter 6 Declare as effective

    Timeline for conducting RCFA


     RCFA to be completed with approval from concerned HOD within 5 days within 10 days
    (working days) of breakdown.
     RCFA which requires external analysis should be completed within 20 working days.

    Initiation and compliance


    Respective Department to initiate RCA based on the kind of incidence and also it should be tracked
    from the BD Notifications
    REVIEWED AND APPROVED BY ISSUED BY DATE

    GM. SECTION HEAD 2115/084/20154


    PIG IRON DIVISION Doc No: WI/MAINT/
    Doc Title: RCA Guidelines
    E,M &I Departmental Page No: 4 of 4
    Manual Revision No: 10

     Monthly MIS on compliance of preventive and corrective actions taken as per RCFA will be
    circulated by respective departments IMS in-charge

    Who should be involved in conducting RCFA.


     Witness (Operator and Shift In Charge’s) at the time of breakdown
     Area In-charge from process and the maintenance departments.
     Operation and maintenance heads( Critical breakdowns)
     RCA review to be headed by Engg Head/GM

    Approval and documentation procedure


     All RCFA’s will follow the standard ISO format available.
     All RCFA’s conclusions and action points to be approved by respective HODs
     Approved RCFA’s to be documented with concerned department IMS Engg and same has to be
    circulated to all Engineers in the concerned departments.

    CAPA Action Points Review


     Each CAPA action point will be monitored by respective HOD`s every month in Department
    meetings..
     Random audits on CAPA Action points will be carried out on a quarterly basis.

    2. DONT’S
    Don’t do any changes without proper change control form.

    3. CONCLUSION

    This SOP is a guideline for Root cause failure analysis and monitoring its effectiveness

    REVIEWED AND APPROVED BY ISSUED BY DATE

    GM. SECTION HEAD 2115/084/20154

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