Root Cause Analysis Training for Supervisors

Root Cause Analysis Training for Supervisors

Root cause analysis (RCA) is a way to determine how a problematic event occurred by examining why, how and when the casual factors happened after the fact.

It’s a methodology that focuses on the genesis of a problem, not the ancillary affects.

RCA is based on the basic idea that effective management requires more than merely “putting out fires” for problems that develop, but finding a way to prevent them. In other words, the primary purpose of root cause analysis (RCA) is to prevent future occurrences of a similar negative event.

Normally, root cause analysis is conducted by a team and led by a supervisor. This team identifies the root cause of a single event and identifies, implements, and evaluates interventions or actions to prevent the event from happening again.

Team members should include staff with direct knowledge of the processes being investigated. Having staff with direct care responsibilities on the team is helpful because they offer the most insight into why the event occurred and what actually happened. Having staff with direct care responsibilities involved, also shifts the focus away from them and finding “who’s responsible” to the system perspective of the underlying root cause.

Some would argue that the RCA supervisor is as important as the RCA process itself. Above all else, a good RCA supervisor (facilitator) should have a passion for problem-solving and enjoy a good challenge.

An efficient RCA supervisor should also think logically and listen very carefully to what others on the team have to say. Other qualities include:

• The ability to assimilate information to form a bigger picture
• Self-awareness to recognize that no one has all the answers all the time
• Good people skills – can relate to all levels of employees and associates such as suppliers, line workers and management
• Adaptable, can adjust approach as needs and situations change

Root Cause Analysis Training for Supervisors Course by Tonex

Root cause analysis training for supervisors covers the principals, tools, and techniques of root cause analysis. It teaches you all the knowledge and skills you would need in order to lead a root cause analysis investigation.

Regardless of the field you are in, whether it is an engineering area, healthcare, or business, we will teach you how to get to the bottom of the problem, identify the most important cause(s), remove or change the cause, and prevent it from happening again in future.

Root cause analysis training provides you the techniques to explore all the potential causes, from human error to equipment failure. Such techniques will help you study complex problems, and help you effectively to stop them from happening again.

Root cause analysis training also will teach you how to guide your team to collect sufficient amount of relevant data, analyze it properly, and generate ideas for solutions. We will train you how to select the most effective solution among all the recommended solutions. Root cause analysis training also helps you supervise the proper implementation of the selected solution, and also teaches you how to develop (or supervise developing) an efficient preventive action plan.

Learn about

• Cognitive interviewing
• Change analysis
• Safeguard analysis
• Critical Human Action Profile (CHAP)
• Problem statement
• Causes investigation
• Root Cause Identification
• Corrective action plan
• Interviewing
• Interviewing Exercise (Human Error/Environmental Issue)
• Human Engineering
• Management System & Changing Behavior
• Change Analysis
• Proactive Improvement
• Trending
• Going from Reactive to Proactive
• Improving Procedures
• Brainstorming techniques
• Fishbone diagrams
• Fault tree analysis
• Preventive plan
• 5 “whys”
• Difference between the RCA and problem solving
• Technical consulting for RCA
• 8D
• Gemba
• Plan, Do, Check, Act (PDCA)
• Cause and escape point
• Pareto analysis
• Mistake proofing (Poka Yoke)

Industries Benefit from Root Cause Analysis Training

Thanks to the extensive evolution in methods and techniques of root case analysis, almost all the industries can benefit from this methodology — In particular:

• Oil, Gas, Refineries
• Mining
• Steel
• Automotive
• Energy
• Manufacturing Plant
• Assembling Manufacturing
• Food and Beverage
• IT
• Healthcare
• Retail & Customer Service

Why Do You Need Root Cause Analysis Training

If your team is involved in troubleshooting, problem solving, or quality control at any level, you must be knowledgeable about the techniques and methods of root cause analysis. You need to know all the basics, principals, and logics behind root cause analysis to be able to guide your team through the process. Root cause analysis training provides you with all you need to develop, conduct, and implement the whole process of root cause analysis. We will teach you how to navigate your team through the steps of data research; data analysis, solutions generation, solution implementation, and corrective/preventive action plan development.

Audience

Root cause analysis training for supervisors is a 2-day course designed for:

• Quality managers/supervisors
• Production managers
• Operations managers
• Product development managers
• IT managers/supervisors
• Business owners
• Regional managers
• Lab managers
• Healthcare managers
• Project engineers
• LEAN supervisors
• Maintenance supervisors
• Safety representatives
• Administrators
• Human resource managers
• Supply chain managers
• Logistics managers/supervisors
• Healthcare managers

Training Objectives

Upon the completion of root cause analysis training for supervisors, attendees are able to:

• Understand the role of root cause analysis in Problem Management
• Define problem statements clear with no ambiguity
• Distinguish an effective root cause analysis from a surface symptoms analysis
• Conduct root cause analysis with flowcharting
• Generate solutions or lead their team to generate solutions
• Investigate complex problems
• Conduct near-miss investigations, incident classification, and data trending
• Understand the basis and fundamentals of root cause analysis
• Lead their team to develop an effective corrective action plan
• Lead an effective and productive brainstorming session
• Lead their team to develop effective fishbone diagrams
• Guide their team to seek out all the possible causes associated with a symptom
• Manage changes
• Lead their team to develop a preventive action plan and implement it

Course Outline

Overview of Root Cause Analysis (RCA)

• What is root cause analysis
• Origin
• Goals of root cause analysis
• Applications
• Collect sufficient, relevant data
• Content vs process thinking
• Types of problems
• Problem Definition – What When Where
• Doesn’t matter “who”
• Causes and timelines
• 5 Whys
• Fishbone diagrams
• Solution brainstorming
• Solution Qualification
• Selecting Effective Solutions

How to Lead the Problem Solving Process

• Problem definition and problem statement
• How do you guide your team toward the right problem?
• Problem identification components
  • Defect Creation
  • Physics of Failure
  • Human Factors
  • Life Cycle Gaps
  • Hidden Failures
• Production plant and equipment failure
  • What reliability engineering tells us about failure
• Lead your team to prioritize
• Develop effective strategies to solve problems
• Causes and their impacts
• Find the roots of a problem
• Be a proactive manager, get ahead of problems
• Tools for studying problems
  • Problem Understanding
  • The Purpose and Applications of Flowcharts
  • Using Flowcharts
  • Checklists
  • Using Critical Incidents
  • Using Performance Matrices

How to Dig Out All the Causes

• Identifying possible causes
• How to remove causes or leave them in the causes list
• Fault tree analysis
• Fishbone diagrams
• How to lead an effective problem cause brainstorming session
  • Problem cause brainstorming
  • The purpose and application of brainstorming
  • Brainstorming recording templates

Data Research

• How to gather the data associated with causes
• Use historical logs
• Use operations logs
• How to use samplings
• Difference between population and sampling
• Use check sheets, graphs, and tables
• Cognitive surveys, interviews, and field observation for opinions
• Problem cause data collection checklist

Analyzing the Collected Data

• Understanding the process of data analysis
• Tools for data analysis
  • Run charts
  • Histograms
  • Pareto diagram
  • Modified scatter diagram
  • Pivot tables
• Tools for soft data
  • Affinity diagrams
  • Relationship diagrams
• Integrative data analysis tools

Accidents Analysis and Role of Human Error

• Multiple incident assessment
• Human-based errors root causes and solutions

Eliminating the Underlying Cause(s)

• DeBono’s Six Hats

Drilling Deep into the Data

• Visualizing variables in three dimension
• Recognizing the key components
• Data comparisons practices

Practicing Some Statistics

• Common statical tests
  • t, F, and ANOVA
• Performing statistics with Excel
• Chi-square method

How You, as the Manager, Can Directly Impact the Effectiveness of Root Cause Analysis

• Root cause analysis is affected by your cognitive biases, as the manager
• Organizational ecosystem impacts root cause analysis
• You must “show” your support

Ensuring the Best Solution is Executed

• Organizing the execution
• Generating corrective and preventive action plans
• Employing tree diagrams
• Embracing changes
• Force-Field evaluation

TONEX Hands-On Workshop Sample

• Practice what you learned on a real case
• Define the problem statement
• Outline the process
• Spot the right problem
• Search for the causes by using the tools taught in the class
• Collect data
• Use check sheets and other methods you learned
• Create sample surveys or interviews
• Use an appropriate method to analyze the data
• Develop an action plan

Root Cause Analysis Training for Supervisors