Root Course Analysis and FMEA

Date : 16/05/2019 - 17/05/2019
Time : 9:00 am - 5:00 pm
Location : The HUB @ Jaya One, PJ-old

Contact Person : Esther Yong
Email : inquiry@knowledgehub-asia.com
Mobile : +012-2662728
Office Tel : +603-7622 0578
Normal Rate : MYR 0.00
Promotion Rate : Contact us for discounted rate.

Introduction

Root cause analysis is a generic term used commonly to refer to structured problem solving within organizations. Root cause analysis of an operations problem, can best be described and defined as the lack of an adequate business process. Because control of operations within organizations is obtained through application of policies and procedures, effective root cause analysis must directly associate the root causes that permit and generate problems with the policies and procedures through which control can be accomplished.

Business processes are the designed ways within an organization through which everything gets done: formally or informally, effectively or ineffectively, safely or unsafely, efficiently or inefficiently. Business processes are the only means by which an organization can manage and focus its activities in the direction of quality and efficiency. When any unwanted event occurs, root cause analysis will discover that there were business processes missing, or ill-suited or unsupported that either generated or allowed the event to occur.

Root cause analysis solution pathways in the final analysis, regardless of what change is to be made within the organization in order to deal with an operations problem, whether it is a human performance issue, or a facility issue, or an operations issue, are always to identify and remedy the business process that governs the activity, so that a change can be made that will not only correct the problem at hand, but also establish a systemic organizational control to avoid recurrence.

Root cause analysis, without this business process perspective to unify the process, can become a confusing collection of labels. Accordingly, there are human factors-styled root cause analyses, barrier root cause analyses, change, cause-and-effect, energy flow, and fault root cause analyses; in fact, without the unifying structure of a business process to link the different kinds of causes into some logical ordered system, there can be as many types of root cause analysis as there are categories of causes.

FMEA is a reliability engineering technique based on the concept of predicting and solving problems before they can occur, thus saving considerable amounts of time, effort and money.

The objective of Root Cause Analysis Training is to impart knowledge to participants on how to accurately describe a problem, take interim corrective actions, analyze all possible root cause of the problem systematically, test root cause, choose correct root causes, take appropriate corrective action, measure effectiveness of corrective action, carry out corrective action impact and update related documentation.

Purpose of the root cause training is to convince the participant thatstructured problem solving will deliver faster and more accurate solutions to problems, and to teach the participant how to solve problems using a simple process but accurate process

The objective of FMEA is to teach the participants to recognize and evaluate potential failure of a process/product and the effects of that failure and also to identify actions that could eliminate or reduce the chance of occurring.

Course Objectives

Upon completion of this program, the participants should be able to:

• Increase customer satisfaction
• Prevent problems
• Improve product / process reliability and quality
• Document risks and actions taken to reduce risks
• Understand the process of identifying categorizing and solving problems or resolving concerns

Course Outline

MODULE 1: INTRODUCTION

• How problem solving first with other improvement initiatives and processes in your plant.

MODULE 2: THE PROBLEM SOLVING PROCESS

• Problem statement
• Data Collection
• Define Facts
• Identify Possible Causes
• Identify True Root cause(s)

MODULE 3: TOOLS USE IN PROBLEM SOLVING

• Optional “tools” to use in problem solving
• Failure modes of common components

MODULE 4: PRACTICAL EXERCISE IN SOLVING PROBLEMS BY ANALYZING ROOT CAUSES

MODULE 5: PROCESS FMEA

• Development of PFMEA
• A structured approach
• Process functions / requirements
• Potential failure modes
• Brainstorming
• Potential effects of failure
• Ranking factors
• Severity
• Potential causes / mechanism of failure
• Occurrence
• Current controls
• Detection
• Risk priority number
• Recommended actions
• Follow-up actions
• Filling up FMEA
• Using FMEA to drive product changes, manufacturing process changes and control plans
• What happens after the FMEA study
• Making FMEA a living document

Methodology

This programme involves a wide range of learning approaches, including self-assessment, case studies, small group activities and discussions, interactive lectures, experimental learning group assignments and exercises and presentation and critique.

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