Reliability Center, Inc. © 2000 Root Cause Analysis: The PROACT™ Approach Presented by: Robert J. Latino Reliability Center, Inc. .

Reliability Center, Inc. © 2000

Root Cause Analysis: The PROACT™ Approach

Presented by:

Robert J. Latino

Reliability Center, Inc.

www.reliability.com


Table of Contents :Table of Contents :

• Reliability Center Inc.• Average ROI of Root Cause Analysis.

• Calculating a Gap

• PROACT Methodology

• PROACT Software, version 2


RCI RCI IntroductionIntroduction

• Founded Allied Chemical’s Corporate R & D Reliability Center in 1972

• Developed “The Reliability Approach to Quality and Productivity”

• R & D focused around Equipment, Process and Human Reliability


IntroductionAverage Returns On Investment

600 - 1000%600 - 1000%

"In essence, RCA "In essence, RCA is FREE!!!" is FREE!!!"


Average Returns On Investment

600 - 1000%600 - 1000%

Inland Steel E. Chicago, IN 3,100% ROI

Eastman Chemical Co. Kingsport, TN 4,200% ROI

LYONDELL-CITGO Houston, TX 17,900% ROI

ROOT CAUSE ANALYSIS: Improving Performance for Bottom Line Results (Latino & Latino, 1999/June, CRC Press, Boca Raton, FL)


Failure Modes & Effects AnalysisCalculate the "Gap"

Actual = 275 Million Pounds/YearActual = 275 Million Pounds/Year

Gap = 115 Million Pounds/YearGap = 115 Million Pounds/Year

Potential* = 390 Million Pounds/YearPotential* = 390 Million Pounds/Year

* Note: Potential is top design capacity or high sustained production over a period of time


Failure Modes & Effects AnalysisDetermining the "Significant Few"

0%

10%

20%

30%

40%

50%

60%

% of Loss Failure Events

80% of loss 20% of loss

RCA PSM - Problem Solving Methods

for Continuous ImprovementRoot Cause

Analysis


Two-Track RCA Approach

EventsEvents

• Principal Analyst Required

• Involves All Levels• Part Time/Full Time

• Root CauseRoot Cause Analysis• Extremely Disciplined/High

Attention to Detail

Significant Few - 80% of LossesSignificant Few - 80% of Losses

• Hourly/Supervisory Level

• Part Time

• Problem Solving Skills• Less Attention to Detail

Random Many - 20% of LossesRandom Many - 20% of Losses100% Coverage100% Coverage

RCA RCA MethodsMethods

PSMPSM


Where do the Events To Analyze Come From?

•RCI’s Modified FMEA Process

•Meridium’s Reliability Suite

•DEI’s SAW (RCM) Program

•CMMS Generated Bad Actor Lists

•EAP/ERP Generated Bad Actor Lists

•Problems detected with a predictive maintenance tools

•Customer Complaint Lists

•Safety Incident Lists

•Quality Defect Lists

•Regulatory Incidents

•Maintenance Logs


IntroductionPROACT™ Methodology

• PRPReserve Event Dataeserve Event Data• OOrderrder• AAnalyzenalyze• CCommunicate Findings & Recommendationsommunicate Findings & Recommendations• TTracking the Results racking the Results

Failure Modes & Effects AnalysisFailure Modes & Effects Analysis

The RCA ProcessThe RCA Process


PReserving Event Data You Need to ...


PReserving Event InformationFive Types of Event Data

The 5 P'sThe 5 P's™™Parts

Position

People

Paradigms

Paper


Ordering the AnalysisRCA Project Flowchart

Develop team charter, critical success factors,

start/end dates

Develop 5 P's™ and data collection assignments

Begin logic tree and assign Begin logic tree and assign verifications to team verifications to team

members (reiterate as members (reiterate as needed)needed)

Develop recommendations and action plans

Write report and make final presentation


AnalyzeThe 7-Step Process

1. Describe the Event

2. Describe the Modes

3. Hypothesize

4. Verify the Hypotheses

5. Determine Physical Roots and Verify

7. Determine Latent Roots and Verify

6. Determine Human Roots and Verify


Three Levels of Cause

Physical Roots Physical Roots Component Causes

Failure Failure AnalysisAnalysis

Human RootsHuman RootsInappropriate Human Intervention

"Witch"WitchHunting"Hunting"

Latent RootsLatent RootsDeficiencies in Management Systems

RCARCA

This is where most asset management programs stop!


• Review of RCI's RCA Process

• Summary of Event

• Description of Event Mechanism

• Logic Tree Review

• Review of Root Cause Action Matrix

• Recognition of Participants Involved

• Question & Answer Sessions

• Commitment to Action Plan

Communicate Findings & Recommendations RCFA Presentation Agenda


Tracking for ResultsAs Proaction Increases...

Production IncreasesProduction Increases Profits IncreasesProfits Increases

Growth & Security Growth & Security IncreasesIncreases


PROACT® SoftwarePlant Engineering Magazine

1998 Gold Award WinnerGeneral & Maintenance Software

Root Cause Analysis System


Root Cause Analysis SystemVERSION 3


The PROACT® System

• PReserving Event Data• Ordering the Analysis

Team• Analyzing Event Data• Communicating

Findings & Recommendations

• Tracking For Bottom Line Results


PReserving Event DataThe 5 P’s

Team Member

File Linking


Ordering the Analysis Team

Easily Assign Members

Team Pool

Quickly Set Permissions by Right-Clicking


Analyzing Event Data

Drag/Drop Logic Tree

Logic Tree Icons

Presentation Mode


Table of ContentsTable of Contents

• Description of Failure Event• Description of Failure

Mechanism• Overview of PROACT™

methodology• Root Cause Action Matrix

I. Executive SummaryI. Executive Summary

• Detailed Recommendations

II. Detailed/Study SectionII. Detailed/Study Section

III. AppendicesIII. Appendices•Recognition of Participant Involved

Additional (Optional)Additional (Optional)

• 5 P’s Data Collection Forms• Team Member Data• Team Charter• Team CSF’s• Team Start/End Dates• Verification Log• Logic Tree

Communicating Findings & Recommendations


Communicating Findings & Recommendations

Custom Report Writer


Tracking For Bottom Line Results

Chart Wizard


PROACT® Training

Problem Solving Methods (PSM) for Business, Industry & Government (1-Day) - For Team Members

Root Cause Analysis Methods for Principal Analysts (3-Days) - For Team Leaders

The Reliability Performance Process (TRPP©) for Managers (1-Day) - For Team Sponsors

Root Cause Analysis Overview for Managers (1-Day) - For Team Sponsors

www.reliability.com

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


What’s The Organization’s Objective?

Desktop Version

Single-User

VS

Enterprise Version

Enterprise Version

Enterprise Version

Enterprise Version

Network (SQL/ORACLE)

USA

Europe

Asia

Latin America

Server


PROACT® 3.0 Enterprise Version

• Establishes Knowledge Management System for Corporation

• Develops World Class Analytical Skills• Results in Drastic Cost Savings and Improved

Performance• Ensures Regulatory Compliance• Significantly Reduces Cycle Times to

Conduct Root Cause Analyses• Produces Quick and Quantum ROI’s

Benefits:


PROACT® 3.0 Enterprise Version

• RCA Database Search Capability• Quality Control Publishing Feature• Team Member Security Options• Drag/Drop Logic Tree Development• File Linking Options• Customizable Report Writer• Importable Team Pool• Enhanced Printing of Logic Tree• Built-In Presentation Mode

Features:


Where 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 Sponsors

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

Reliability Center, Inc. © 2000 Root Cause Analysis: The PROACT™ Approach Presented by: Robert J. Latino Reliability Center, Inc. .

Documents

latino reliability center

human reliability slide

reliability approach

rca process slide

fl slide

period of time slide

roi root cause analysis

final presentation slide