Root Cause Analysis Training

Failures. accidents and near misses can be costly in terms of lives, injuries, damages and lost hours.  It is therefore that every such incident is properly investigated to the maximum extent and the right inferences and causes drawn.

Root Cause Analysis is a structured approach to fault analysis.  It starts from the incident and thoroughly goes through all possible causes and reasons.  Root Cause Analysis ensures that no cause however minor is left out and that all reasons are identified and properly documented.  This ensures that the incident does not recur.

Engineers and Managers trained in Root Cause Analysis will be able to systematically follow up on any abnormality or deviation and prevent serious accidents or failures.  This increases safety and reliability of operation.

Benefits to your organization with Root Cause Analysis Training

  • Improve Safety and Reduce Losses due to accidents and failures.
  • Make Financial Savings due to reduction in downtime due to accidents and product recalls.
  • Develop a Reliable Failure Analysis system for the organization.
  • Improved Quality of products or services, increased customer satisfaction, and a better reputation in the marketplace.

Duration: 2 days
Mode: Classroom / Online
Deliverables: CourseWare Hard/ Soft Copies






Learning Objectives

  • Enhance problem solving effectiveness by providing a model for more deeply analyzing problem situations.
  • Clarify the difference between analytical and creative thinking, and when each is most useful.
  • Promote the ability to provide problem-solving support in situations where one is not an expert in the process or technology involved.
  • Expand the range of tools available for analysis of problem situations.

Course Contents


Day 1: Foundations & RCA Methodologies
  • Module 1: Introduction to Root Cause Analysis
What is RCA? Purpose and business impact
RCA vs. troubleshooting – understanding the distinction
When to apply RCA in manufacturing

  • Module 2: Types & Classifications of Causes
Symptoms vs. causes vs. root causes
Classification: human error, machine failure, process issues
Case walkthrough: The hidden cost of not identifying the root cause

  • Module 3: Tools & Techniques for RCA
5 Whys analysis (interactive group exercise)
Fishbone (Ishikawa) Diagram: cause categorization
Pareto analysis: prioritizing issues by impact
Fault Tree Analysis (FTA): logic-based failure modeling

  • Module 4: Data Collection & Verification
What data matters: sources in a manufacturing context
Techniques: interviews, process walk-throughs, observation
Avoiding confirmation bias during problem investigation

Day 2: Application, Action Planning & Culture Integration
  • Module 5: RCA in Action – Case Simulations
Facilitated group activity using a real-world case study
Cross-functional RCA team simulation
Presenting findings: cause mapping, visuals, and narration

  • Module 6: Developing Sustainable Corrective Actions
Writing effective CAPA plans
Preventive actions vs. firefighting
Assigning responsibility and tracking implementation

  • Module 7: RCA in a Lean/TPM/Six Sigma Environment
Aligning RCA with ongoing improvement systems
RCA role in OEE improvement and downtime reduction
Integrating RCA into daily Gemba walks

  • Module 8: Sustaining RCA Culture
Promoting a "no-blame" culture for continuous improvement
Coaching operators and supervisors in RCA thinking
RCA dashboard: tracking success, KPIs, and ROI


Format

This two-day, in-person course offers an interactive learning environment and a high level of instructor support when using particular tools to ascertain the origin of an issue and suggest potential remedies.





Why choose us


At the Institute of Corporate Analytics and Training, we have trained over 5000 professionals on a wide range of corporate and management trainings from many organizations and companies, from diverse domains,  around the world.  We have a team of highly motivated and experienced team of trainers.  Our trainings are designed to blend theoretical concepts with field experience.  The concepts and techniques you will learn will be illustrated with case studies from the field, role plays and simulations.

Rest assured that at the end of the training programs, you will emerge confident and energized armed with skills and knowledge as well as the techniques of applying them.

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