Reliability Consulting Services: RCA CONSULTING

RCI consultants work as strategic partners to help clients identify and solve problems so they can experience an increase in precision, productivity, and profitability. For information call 804-458-0645 or email info@reliability.com.

(FMEA) Failure Modes & Effects Analysis	(OA) Opportunity Analysis	Plant Reliability Assessments	Maintenance Reliability Assessments
PROACT® Performance Process Model	Customized Consulting Services	Custom Training

Root Cause Analysis Consulting and Facilitation Many clients trained in Root Cause Analysis choose to be mentored during their first attempt at resolving the causes of a major undesirable event. Additionally, corporations experiencing chronic high-impact problems often want assurances that the best techniques are used to arrive at answers. RCI can provide Facilitator’s to lead and assist client Lead Investigators on conducting Root Cause Analyses. In this capacity our seasoned Facilitators are experts in the PROACT investigative methodology. They will lead a client RCA team adhering to the rules of the PROACT methodology using the client’s Subject Matter Experts (SME). Our goal as facilitators will be to channel all of the expertise of the team in such an organized fashion that the path(s) to failure are uncovered using documented evidence. In the event that the client does not have required SME’s for the RCA at hand, RCI can provide various expertise (metallurgists, mechanical equipment, electrical equipment, human error, etc.) as SME’s to support the RCA team. Such expertise is available on an as-needed basis. RCA Case Histories More Information

1st Movie in the NEW RCA Library Learn how one RCA team used the PROACT Methodology and Software to analyze the root causes of one of their significant down hole well failures at their producing field. This short movie will carry you through the cause-and-effect logic the team used to arrive at their conclusions. See how easy it was for them to communicate their findings to their management in a disciplined, logical and easy to follow format! Click here to watch the movie: See ALL previous movies, tools and the entire PROACT Series:

Basic Failure Modes & Effects Analysis (FMEA) Facilitation

RCI can provide Facilitators to lead and assist client Lead Analysts on conducting Basic Failure Modes and Effects Analyses (FMEA). Our Facilitators will guide the team through the development of the Process Flow Diagram, the value tables for measuring Risk (Probability x Severity) and creating the spreadsheet to input the subjective values for potential modes of failure. The deliverable will be a Risk Assessment of a selected process where the Significant Few are identified. The Significant Few are the 20% (or less) of the potential modes that represent 80% of the risk of the process. As a result of knowing this risk distribution, decisions will be made about recommendations on how to reduce the risk.

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Opportunity Analysis (OA) Facilitation

RCI can provide Facilitators to lead and assist client Lead Analysts on conducting Opportunity Analyses (OA). Our Facilitators will guide the team through the development of the definition of failure/loss, Process Flow Diagram (PFD), the frequency of occurrence per year, the indicators that impact the process (i.e. – labor, materials, downtime, etc.), the assumptions used to measure the impact (i.e. – labor rates, cost/hr of downtime in the process, etc.), and creating the spreadsheet to input the historical data. The deliverable will be a report where the Significant Few are identified that are of the causing the most losses currently to the system. The Significant Few are the 20% (or less) of the actual modes that represent 80% of the actual losses in the process analyzed. As a result of knowing the distribution of the expenditures due to failures, identifying the candidates for RCA is made based on quantitative impact to the current process.

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Plant Reliability Assessments

RCI examines both the hard and soft issues that are barriers to establishing a reliability environment within a given facility. The assessment report includes recommendations that address solutions to the major stumbling blocks identified by management, and is delivered on the last day at the site. Final assessment usually takes 7-10 calendar days, depending on facility size, with hard copies transmitted within a week after hearing and reviewing management comments.

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Maintenance Reliability Assessments

Maintenance studies focus on issues that directly affect process equipment reliability. The first priority is to evaluate a facility's ability to perform precision overhauls, assemblies, and installations. The next is to determine their ability to perform the necessary inspections to assure equipment integrity. Other studies include quality assurance of spare parts, process equipment accessibility, tooling, and skill in using failure analysis techniques. Finally, RCI reports on any restraining paradigms which may be acting as barriers to reliability.

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PROACT® Performance Process Model

The PROACT Performance Process Model® views Root Cause Analysis (RCA) as a comprehensive system requiring organizational support, assimilation with existing initiatives and culture, specific well-rounded knowledge and skill sets of the RCA Principal Analysts (PA), and a lessons learned feedback system about RCA results. 

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Customized Consulting Services

Each RCI client operates under a unique set of circumstances, and their facilities have their own unique operating characteristics accordingly, RCI's consulting services are tailored to meet the one of a kind needs of its clients. Each assignment begins with a clean page, with no pre-formed judgments. RCI's aim is to become a junior associate, lending our experience and talents to helping clients achieve their specific agendas. We take pride in our ability to truly serve client needs and in seeing our client-associates achieve outstanding profits. Our goal is to make the cost of our services a small percentage of the overall return.

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Custom Training

RCI will tailor its training to fit client needs and prior training. Our approach consists of various training segments. which can be mixed and matched to meet specific goals. Additionally, RCI will often create a new segment to match a particular client. We have a strong R&D department. and are always creating and developing new reliability training materials, new upgrades to existing material, and new ways of teaching the material.