Scribd Logo
Upload

Welcome to Scribd!

  • 304 views

    RCI Root Cause Investigation

    Uploaded by

    Carlos Jose Sibaja Cardozo
    The document discusses implementing a team-based approach to improve root cause investigations of equipment failures at a company. It overhauled the root cause process, establishing clear guidelines and extensive training. This resulted in significant improvements such as reducing repeat failures below 5% and cutting related waste from $17 million to $1.8 million.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    RCI Root Cause Investigation

    Uploaded by

    Carlos Jose Sibaja Cardozo
    304 views24 pages
    The document discusses implementing a team-based approach to improve root cause investigations of equipment failures at a company. It overhauled the root cause process, establishing clear guidelines and extensive training. This resulted in significant improvements such as reducing repeat failures below 5% and cutting related waste from $17 million to $1.8 million.

    Original Description:

    investigación y análisis de falla

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses implementing a team-based approach to improve root cause investigations of equipment failures at a company. It overhauled the root cause process, establishing clear guidelines and extensive training. This resulted in significant improvements such as reducing repeat failures below 5% and cutting related waste from $17 million to $1.8 million.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    304 views24 pages

    RCI Root Cause Investigation

    Uploaded by

    Carlos Jose Sibaja Cardozo
    The document discusses implementing a team-based approach to improve root cause investigations of equipment failures at a company. It overhauled the root cause process, establishing clear guidelines and extensive training. This resulted in significant improvements such as reducing repeat failures below 5% and cutting related waste from $17 million to $1.8 million.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 24

    Team Root Cause Investigation

    Achieving a Step Change


    Improvement in Performance
    By
    Mike Mastic, Dow Chemical Company
    and
    Chris Eckert, Apollo Associated Services

    Equipment Reliability - Track 3


    1

    Root Cause Investigation


    Presentation Outline
    Where Were We
    The Case for Change
    The Results
    The Team Concept
    The Work Process
    Quality Assurance
    Suggestions for Your Program
    Q&A
    2

    Where Were We
    As a Corporation
    Pockets of expertise
    Customized Apollo training
    Corporate trigger list
    Good electronic tools available globally
    Customized RCI programs by business
    All similar, yet all different
    All have strengths and weaknesses
    3

    Where Were We
    In Our Particular Business
    For the facilitators, RCI = Burden
    For those involved, RCI = Punishment
    Ineffective facilitation
    Hesitancy to deal with behavior issues
    Ineffective corrective actions
    Check-the-box validation
    4

    The Case for Change


    2004 Before
    % repeat
    events

    >10%

    Event severity

    High

    # Quality
    Incidents

    >150

    $$ Waste

    $17MM

    Culture

    Redefining
    Normal

    The Results
    2004 Before

    2007 After

    % repeat
    events

    >10%

    <5%

    Event severity

    High

    Much Lower

    # Quality
    Incidents

    >150

    35 in 2007
    11 in 2008 YTD

    $$ Waste

    $17MM

    $1.8MM

    Culture

    Redefining
    Normal

    Self Sustaining
    Program

    The Team Concept


    Defining the Vision
    Vision for the RCI Program
    Disconnect RCI from punishment
    Highly trained & capable facilitators
    Common finished product regardless of
    facilitator
    Documented work process
    Eliminate unplanned events
    Address behavior issues appropriately
    Monitor performance metrics
    Change the culture
    7

    The Team Concept


    Defining the Vision
    Vision for Facilitators

    Facilitation is a desired skill set


    Facilitation is fun
    Provide extensive training & mentoring
    Facilitators must demonstrate proficiency
    Remove the burden
    Partnership Concept Facilitator & Event Owner
    Avoid burn out
    8

    The Team Concept


    Draw Your Own Box
    Vision was in place but no action
    I decided to act
    Key Take-Away
    Dont wait for someone else
    Lead and others will follow

    I framed the program, but was open to


    input from others
    9

    The Team Concept


    Securing Leadership Support
    It was easy The business
    leader was ready
    Already had Quality & EH&S
    Leaders support
    Presented vision and scope of
    effort
    Asked for resources & support
    10

    The Team Concept


    Assembling the Team
    Determine size of team
    Number of events
    Capacity of the organization

    Leaders identified potential candidates


    Informed and approached candidates
    Training available
    Limit number of RCIs per month
    There is an end in sight 2 year terms
    11

    The Team Concept


    Team Leadership
    Focal point for all RCI requests
    Ensure trigger is met
    Communicate pre-work expectations
    Identify facilitator
    Lead team meetings
    Oversee training & mentoring process
    12

    The Team Concept


    Training & Mentoring
    Apollo RCA for Practitioner
    RealityCharting software
    Mentoring process
    The stamp of approval
    Succession planning

    13

    The Team Concept


    Recognition
    After proficiency is demonstrated
    Monetary
    Electronic / Public

    14

    The Work Process


    Trigger Criteria
    Event Owner contacts RCI Team Leader
    Team Leaders guide
    RCI Team facilitates significant events
    Minor event exceptions

    Reasons to increase thresholds


    Success as a trigger
    Dynamic analysis
    15

    The Work Process


    Preparation & Pre-Investigation
    Standardized documents
    Evidence collection & analysis
    Behavior issues
    Team Leader identifies facilitator
    Formal meeting scheduled (2 hour min)

    16

    The Work Process


    Facilitation
    We use Apollo RCA methodology &
    RealityCharting software
    Facilitators as independent third party
    Outside area of expertise
    Behavior issues
    Facilitator control - Dont rush the process
    17

    The Work Process


    Documenting
    Facilitator sends reports & files to Event
    Owner
    RealityCharting file
    Cause & effect chart export Adobe
    Final report with solutions export to Word
    Action item list export to Word

    Event Owner documents event in


    electronic reporting tool
    18

    The Work Process


    Leveraging Learnings
    During RCI Add to action item list
    Add to electronic database
    Monthly incident sharing with staff
    Weekly safety meetings with operations
    Leveraging the team concept

    19

    Quality Assurance
    RCI Effectiveness
    Six Sigma project results
    Effectiveness criteria
    Reporting

    20

    Quality Assurance
    Event Validation
    Last piece of program for our business
    Validation Team
    Production and Quality Leaders
    6 Month waiting period
    Action item review

    Will lead to step change in performance

    An RCI Program without effective validation


    is just practice
    21

    Suggestions for
    Your Program
    Mikes Key Take-Aways
    Dont wait
    It wasnt hard
    The team helped build the work process
    and documentation
    Program is still evolving
    Personal recognition
    Value of the team
    22

    Suggestions for
    Your Program
    Chris Key Take-Aways
    You dont have to be a Sr. Manager to Lead!
    Most people hesitant to lead, but happy to follow
    Having Trouble Engaging Operations with your Reliability Efforts?
    RCA yields fast, visible results. Operations will notice

    Build the infrastructure first


    Work Process
    Incorporate R&R into personal goals
    Training & mentoring pay off
    Shortcutting will cost you far more

    The Front Line: Engage Listen Act.


    Measure Results & Share Success w/ Leaders
    Savings & Effectiveness
    23

    Questions?

    24

    You might also like