Root Cause Analysis:

The PROACT Approach

Presented by:
Robert J. Latino
Reliability Center, Inc.
www.reliability.com
Reliability Center, Inc. 2000
 Table of Contents :
Reliability Center Inc.
Average ROI of Root Cause Analysis.

Calculating a Gap
PROACT Methodology

PROACT Software, version 2

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 RCI
Introduction

Founded Allied Chemicals Corporate R

& D Reliability Center in 1972
Developed The Reliability Approach to
Quality and Productivity
R & D focused around Equipment,
Process and Human Reliability
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 Introduction
Average Returns On Investment

600 - 1000%

"In essence, RCA

is FREE!!!"

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 Average Returns On Investment

600 - 1000%
ROOT CAUSE ANALYSIS: Improving Performance for Bottom
Line Results (Latino & Latino, 1999/June, CRC Press, Boca
Raton, FL)

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

Eastman Chemical Co. Kingsport, TN 4,200% ROI
LYONDELL-CITGO Houston, TX 17,900% ROI
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 Failure Modes & Effects Analysis
Calculate the "Gap"
Potential* = 390 Million Pounds/Year

Gap = 115 Million Pounds/Year

Actual = 275 Million Pounds/Year

* Note: Potential is top design capacity or high sustained

production over a period of time
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 Failure Modes & Effects Analysis
Determining the "Significant Few"
% of Loss Failure Events

60%

RCA 50%

40%
PSM - Problem Solving Methods
Root Cause
for Continuous Improvement
Analysis 30%
20%

10%

0%

80% of loss 20% of loss

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 Two-Track RCA Approach

Principal Analyst Root Cause Analysis

RCA Required Extremely Disciplined/High
Methods Involves All Levels Attention to Detail
Part Time/Full Time

Events Significant Few - 80% of Losses

100% Coverage
Random Many - 20% of Losses

Hourly/Supervisory Problem Solving Skills

PSM
Level Less Attention to Detail
Part Time

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Where do the Events To Analyze Come From?

RCIs Modified FMEA Process

Meridiums Reliability Suite
DEIs 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
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Introduction
PROACT Methodology

Failure Modes & Effects Analysis

The RCA Process

PReserve Event Data
Order
Analyze
Communicate Findings & Recommendations
Tracking the Results
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PReserving Event Data You Need to ...

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 PReserving Event Information
Five Types of Event Data

Parts
The 5 P's
Position
People
Paradigms
Paper

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 Ordering the Analysis
RCA Project Flowchart

Develop team charter,

Develop 5 P's and data
critical success factors,
collection assignments
start/end dates

Begin logic tree and assign

verifications to team
members (reiterate as
needed)

Develop recommendations
and action plans

Write report and make final

presentation
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Analyze
The 7-Step Process

1. Describe the Event

2. Describe the Modes

3. Hypothesize

4. Verify the Hypotheses

5. Determine Physical Roots

and Verify

6. Determine Human Roots

and Verify

7. Determine Latent Roots

and Verify
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 Three Levels of Cause
This is where
most asset
management
programs stop!

Failure Physical Roots

Analysis Component Causes

"Witch Human Roots

Hunting" Inappropriate Human Intervention

RCA Latent Roots

Deficiencies in Management Systems

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 Communicate Findings & Recommendations
RCFA Presentation Agenda

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

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Tracking for Results
As Proaction Increases...

Production Increases Profits Increases

Growth & Security

Increases

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 Root Cause Analysis System

PROACT Software
Plant Engineering Magazine
1998 Gold Award Winner
General & Maintenance Software
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 Root Cause Analysis System
VERSION 3

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The PROACT System
PReserving Event Data
Ordering the Analysis
Team
Analyzing Event Data
Communicating Findings
& Recommendations
Tracking For Bottom
Line Results

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 PReserving Event Data
The 5 Ps

Team
Member

File
Linking

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Ordering the Analysis Team

Easily
Assign
Members
Team Pool

Quickly Set
Permissions
by Right-
Clicking

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 Analyzing Event Data

Drag/Drop
Logic Tree
Logic Tree
Icons

Presentation
Mode

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Communicating Findings &
Recommendations
Table of Contents
I. Executive Summary Additional (Optional)
Description of Failure Event
5 Ps Data Collection Forms
Description of Failure
Team Member Data
Mechanism Team Charter
Overview of PROACT
Team CSFs
methodology Team Start/End Dates
Root Cause Action Matrix
Verification Log
II. Detailed/Study Section Logic Tree

Detailed Recommendations

III. Appendices
Recognition of Participant Involved

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Communicating Findings &
Recommendations

Custom Report
Writer

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Tracking For Bottom Line
Results

Chart Wizard

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

The Reliability Performance Process

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

Root Cause Analysis Methods for

Principal Analysts (3-Days) - For
Team Leaders
Problem Solving Methods (PSM) for
Business, Industry & Government
(1-Day) - For Team Members

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Whats The Organizations Objective?
Asia
Enterpri
se
Version

Desktop Latin America Europe

Version
VS Enterpri Enterpri
se Server se
Version Version

USA
Single-User Enterpri
se
Version

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 PROACT 3.0 Enterprise Version
Benefits:

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 ROIs

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PROACT 3.0 Enterprise Version
Features:
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

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Root Cause Analysis Methods for
Principal Analysts (3-Days) - For Where Do
Team Leaders (A.C.R.) We Go
PROACT Software Training (1-
From
Day) - For PROACT Users
Here?

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

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