Root Cause Failure Analysis for Effective Problem Evaluation (PST103)

20 September 2017 - 21 September 2017

Root Cause Failure Analysis For Effective Problem Evaluation
(Based on the Construction Logic of 5 Why Methodology and 8-Steps of PM Analysis)

INTRODUCTION
1. 5 Why Logic is the basic construction logic applied in many Root Cause Analysis tools. However, the theory and proper application of 5 Why has been loosely applied in an incorrect way. This leads to incorrect analysis and incorrect corrective actions.

2. Ask anyone on “What is The Root Cause of a Problem”. The chance is the reply will be from a vague understanding to a weak identification of the physical causes that affect the overall system of a problem. Learning Root Cause Analysis in the beginning of understanding:
• What is A Root Cause?
• Where to Find the Root Cause?
• How to Search for It?
• What Kind of Solution is Required to Counter It?
• And of This is Done, Will the Problem Go Away?

3. In every problem there are physical causes that need to be investigated for their contribution to the primary problem. Identification of physical causes requires not only an understanding of the current situation, operational technical know-how, but also a systemic way to organize the Root Cause Analysis. This is one of the most important aspects of problem solving.

4. Root Cause Analysis is an investigational approach to search for the core problem where one or several physical roots are hidden.

5. The intend of this course is to meet the need of industry for a thorough understanding:
• How to Apply Root Cause Analysis to Different Type of Problem
• What are the Mapping Methodology and Their Related Applications
• How to Find the Root Causes and Eliminate Them
• How to Generate the Solutions for Solving the Core Problem Issue
• How to Quickly Identify Key Determinant Factors Affecting the Quality of a Process
• How to Quickly Identify the Key Determinant Factors of a Product Design

OBJECTIVE
• Teach participants the 8-step Root Cause Analysis Structure
• Illustrate each of the 8 steps and explain how they can be put into practice
• Provide hands-on approach on how to conduct a proper physical analysis of the problem
• Identify the key constituent condition of each core issue
• Provide an investigational method of reveal abnormality and defective conditions
• Provide an investigational method to reveal core problem and physical root cause
• Provide a search method for X-solution
• Complete documentation for use in root cause analysis

COURSE OUTLINE
MODULE 1: HOW MANY PROBLEM TYPE CAN YOU FIND
The course starts with discussion on many problem types and how they are characterized
• What are the problem type
• Can you control them
• Can you manage them
• Can you solve the problem

MODULE 2: THE 5-WHY METHODOLOGY
• Under what context is 5 Why used
• 5 Why a focusing method
• 5 Why – Closed System
• 5 Why – Open System

MODULE 3: THE LEVEL OF INNOVATION
Often Technical Solutions are developed at many levels. How do we distinguished one level from another
• X Solution Level
• Y Solution Level
• Z Solution Level
• N Corrective Action Level

MODULE 4: HOW TO DESCRIBE TECHNICAL SYSTEM PROBLEM
• What is a phenomena
• How to describe a phenomena
• The purpose of phenomena
• Practice Sessions

MODULE 5: HOW TO CONDUCT A PHYSICAL ANALYSIS
• What is physical analysis
• The 5 Why Logic
• The physical analysis logic
• Establishing the most likely possibilities

MODULE 6: PREPARING THE PHYSICAL ANALYSIS DOCUMENTATION
• The Function
• What has changed
• The Measurement
• The physical analysis model

MODULE 7: IDENTIFYING THE CONSTITUENT CONDITIONS AND THE PHYSICAL ROOTS ON DOCUMENT A
• What are the Constituent Conditions
• Establishing the casual factors
• The primary correlation
• The secondary correlation

MODULE 8: THE ROOT CAUSE ANALYSIS STRUCTURE
• The established root cause structure
• Establishing the physical roots
• Establishing the human roots
• Establishing the latent roots

MODULE 9: HOW TO CONDUCT DEFFECTIVE CONDITION SURVEY ON DOCUMENT B
• The optimal standards
• The checking methods
• Use of special devices
• The abnormality checks

MODULE 10: HOW TO GENERATE EFFECTIVE SOLUTION
• Tool attributes
• Part attributes
• Material attribute
• Force attribute

MODULE 11: THE CORRECTIVE ACTIONS & THEIR RELATED DOCUMENTATION
• The containment solution
• The interim solution
• The permanent corrective action
• The preventive measures

MODULE 12: THE ROOT CAUSE FAILURE ANALYSIS REPORT
• How to fill up the report
• Participants compile all analysis on the 6-page report for customer compliance
• Group presentation
• Instructor’s comments

WHO SHOULD ATTEND
This course is applicable to all level of executives, from senior managers to executives. All functional executives from System, Engineering, Production, Marketing, Purchasing and Human Resource can benefit from applying Root Cause Analysis in their work. Those who want a quick way to identify key determinant factors for DOE will also benefit. Conducting Root Cause Analysis is only an essential component of Six Sigma training.

TRAINER’S PROFILE
Sabrina Lim has a Bachelor in Engineering (First Class Honours) from The University of Sydney. She was attached to well-known American MNCs where she had hands-on experience in the Quality, Quality Systems and Process Engineering.

Her success in her career include ISO9000 recertification, taking responsibility for product transfer from the US, troubleshooting new product quality problems and involvement in in-process yield improvement programmes, developing training materials, calibration systems, new product specifications and standard operating procedures.

She has been involved in teaching and training for the past nine years and has conducted trainings in quality, quality systems and technical areas. Her hands-on experience in manufacturing as well exposure in training personnel from diverse industries in Malaysia and Singapore enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena.

DURATION
2 days

COURSE FEE
Program 100% claimable under SBL Scheme
PSDC Members: RM 690/pax
Non-Members: RM 750/pax

*All prices listed above are subjected to GST effective 1st April 2015