June 19, 2018
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PROACT® Root Cause Analysis Lead Investigator Series

Five Workshops Formatted for Industry

PROACT® Root Cause Analysis Lead Investigator Series will provide analysts with a solid foundation in mechanical/electro-mechanical reliability (fractology) and an in-depth understanding about the conditions that increase the risk of human error in the workplace. All of these integral skills will then be utilized within the PROACT® RCA Methodology framework and software, to ensure investigations are efficient, effective and successful.

 

 

Benefits & Features:

  • Five workshops over a period of time that is determined by the client. Training workshops can be back-to-back and all sequential or they can be spread over time…it is whatever works best for the client.
  • Real case studies and failed parts to review, presented by veteran analysts.
  • Workshop reference materials correlated to each workshop.
  • Students are encouraged to bring real time example issues to share in class and to serve as the focus of exercises.
  • Upon completion of all courses in this series analysts are acknowledged as Certified PROACT® Lead Investigators.
  • Workshops are available on client sites or RCI Training center.

Course Descriptions:

PROACT® Root Cause Analysis Methodology:

RCA facilitators will learn to lead teams to analyze why undesirable events occur, all the way down to their systems root causes. The goal is not to pinpoint WHO makes poor decisions, but WHY such decisions are made. This methodology is applicable to anyone in EH&S, Quality, Reliability, Maintenance, Engineering and Administration.

Justification Tools & Techniques:

This course provides an in-depth understanding of RCI’s Failure Modes & Effects Analysis (FMEA) & Opportunity Analysis (OA) approach to identifying the most significant opportunities in any system. The course is designed to provide a vehicle to comb existing weak operating systems in order to find the details associated with the weaknesses thereby exposing the opportunities for improvement. A detailed comprehension of how to perform FMEA/OA on the weak systems will be applied so the maximum bottom-line results can be achieved. The attendees will learn how to physically perform an FMEA/OA, as well as, how to develop a report that details the FMEA results, and how to present their findings to management for review and action.

The course will also cover Force Field Analysis & Decision by Pairs which is a technique used to prioritize a list of items in their order of importance to the decision makers. The technique measures each item with all the other items to provide a structured model for determining their order of importance in the overall scope of the decision making process.

Human Error Reduction:

Human Error Reduction is designed to provide students with the requisite skills and knowledge necessary to effectively reduce human error in the workplace. With fewer errors made by your staff, you will spend less time correcting human errors and responding to consequences of human errors, thus strengthening your facility’s safety culture. This workshop provides the students an acute awareness to the conditions that increase the risk of human error. This workshop is intended to be proactive in nature because students will be able to identify environment health and safety conditions that are high risk, and implement countermeasures to reduce those risks.

Failure Scene Investigation for Mechanical:

This course provides an in-depth understanding of how to verify hypotheses developed in RCA. Hands on presentations are made to teach students how to identify mechanical failure modes by reading fracture surfaces. This workshop can be customized per client interest and focus. For instance, the client can chose to focus on bearings, gears and fans or they may wish to focus on seals, shafts and fasteners. Many of the root causes of failures and risks lie in the mechanical reliability of equipment and components. This workshop will educate the students with a much deeper understanding of the material sciences and their role in failure.

Lead Investigator Facilitation & Mentoring:

This workshop will take all the knowledge learned from the past 4 workshops and put them together to solve specific issues. These issues will be identified using the FMEA and OA tools learned. The most important and highest ROI events will then be analyzed using the PROACT RCA methodology and software. The result will be an instant pay back for the investment in the training itself.

PROACT® Software & Knowledge Management Templates:

Failure analysts require a consistent, structured approach for conducting their investigations. Including a software component in this process will consistently guide the analyst through the analysis and also prepare management reports of the findings and recommendations. Additionally it will cut analysis time in half. The PROACT Suite contains the following:

  • LEAP® FMEA/OA Software provides a disciplined approach to documenting and communicating a Failure Modes and Effects Analysis (FMEA) and an Opportunity Analysis (OA). While the FMEA allows for compliance to regulatory guidelines. OA will allow the users to explore trends for chronic events that are the most prudent to conduct Root Cause Analyses on. LEAP also will record all of these analyses in a common
  • PROACT® RCA Software guides and helps facilitate the disciplined RCA process taught in the facilitator training. This software eliminates the need for multiple programs to attain the end result. PROACT RCA software documents the RCA process while dynamically compiling the report behind the scenes. It also includes a built-in presentation mode. PROACT RCA Software serves as a knowledge management system by storing successful RCA’s and their associated logic, and allowing users to search and learn from them. Special securities allow the analyst the ability to limit permissions to the ongoing analysis and to publish the analysis for all to see when approved by legal.
  • The PROACT® RCA Templates are an aggregation of over 40+ years of experience associated with hundreds of field investigations. The analyses have been thoroughly reviewed and their results compiled to form this unique, single knowledge base of  300+ RCA templates encompassing five main areas: operational, mechanical, electrical, quality, & human. As analysts use RCI’s PROACT ® Software and have exhausted their ideas for developing hypotheses, there are more opportunities available with the PROACT ® Logic Tree Knowledge Base templates. These templates provide the analyst the ability to see if there may be something they could have missed. The PROACT ® RCA templates provide learning based on past experience and also a system of “checks-and-balances” for the comprehensiveness of the analysis. While no knowledge base can ever cover all of the potential variables of all  events, analysts can learn from past experience to assist with preventing recurrences of similar events.

Download FACT Sheet


Public RCA Method Training Schedules: Register Today!

Private Training? Contact RCI

Visit Our Training Areas:

Root Cause Analysis Methods
Failure Scene Investigation
Basic Failure Analysis
Lead Investigator Series
Human Error Reduction
FMEA / OA Risk Management

What Our Clients Say…

Reda A-Admawi

The PROACT® Logic Tree, is one of the best methods we use. We are proud that all SABIC sites and corporates are unified in terms of analyzing the major incidents by using PROACT® Logic Tree methodology since our aim and target is always to reach to the latent root cause(s) that failed to protect our assets from any false human interaction.

Reda A-Admawi, RCA Specialist
SABIC

Ron Butcher

“I had the opportunity to attend the Reliability Center’s (PROACT) Lead Investigator course in 2012 when we used “super users” to perform RCA’s on high impact incidents. One of the things I most enjoyed about that course was the time spent on the investigative process and the formality of evaluation of evidence based on facts in evidence. While that sounds a tad like a criminal investigation, the course is really about instilling the formal processes necessary for exploration and understanding. To your ‘wheelhouse’ we had a wonderful three days where we did nothing but evaluate and hypothesize the failure mechanisms for an array of mechanical components, shafts and bearings. From the perspective of understanding failure to institute system resilience, I can’t honestly say enough good things about the course. I also don’t think we’d find a more experienced team in performing these analyses than exists with the Latino family whose father started the business long before it was a fashionable practice. From my reading and experience, I would put Mr. Latino on par with Dr. Deming, Joseph Juran and others who pioneered the quality movement. Simply stated, whatever platform is used to collate and present the findings will only be as beneficial to our cause as the preparedness of the investigative team.”

Ron Butcher
Director of Health and Safety
U.S. Competitive Generation
AES

Allan McNally

“I have had the opportunity of using various methods such as 5-Why’s, Fishbone, Apollo, FMEA, and PROACT. I feel PROACT meets my expectations. The PROACT methodology uses rigorous fact based data followed by a verification process to determine the physical, human & latent root-causes that led to the failure(s). It can be used by people on the floor as well as any engineer that wishes to use the methodology.

Allan McNally
Machinery Reliability Consultant

Curtis Lane

“Most important thing I learned was using the power of data to manage the RCA process.”

Curtis Lane
Georgia Pacific

Kraig Grivette

“The course gives good examples of where to start an investigation and also showed how starting in the wrong spot will cost you more”

Kraig Grivette
United Taconite

Mark Young

I just wanted to say how much I appreciate your company and the products you offer. We’ve incorporated your RCA Methodology into our business and are having a very smooth roll-out. I would like to especially recognize John Bartlow as being a “5 star asset” to your organization. In my opinion, he defines “excellence” within customer service. I look forward to tremendous success working with you guys, just as I’ve had success in the past.

Mark Young
Director of Reliability - Advanced Technology Services

Thomas Bublitz

Very complete course on how to perform RCA from start to finish. Real life examples of problems are excellent in making connections.

Thomas Bublitz
Herman Miller, Inc.

Doug Plucknette

“PROACT RCA – A technique that allowed us to fix a chronic processing problem that plagued one of our gas plants for more than ten years. If not for this technique, we would still be fire fighting this problem today.”

Doug Plucknette
Eastman Kodak

Tim Stovall

As assets become more sophisticated, and we become more reliant on machinery, human error (and the reasons for it) are a far greater part of the reliability picture. This book will provide even greater support to companies that want to get the most out of their physical assets, and the PROACT methodology will continue to deliver unique value as they continue to evolve the method.

Tim Stovall, CMRP, Reliability Leader
NOVA Chemicals, Inc.

Reginald Gullette

I definitely learned new ways / improved ways to think while troubleshooting on the job. It inspired me to break away from staying in the box mindset.

Reginald Gullette, E/I Engineer
Mead Westvaco

Marcus Mukete

We received in depth analysis techniques, knowledge of mechanical failure modes and really good insight to human error analysis.

Marcus Mukete, EHS Projects Division
AES

Pam Grant

MedStar Union Memorial Hospital

Wonderful system! Presentation was done in a very consistent manner giving a good overview of system and capabilities. The real case scenario exercise was a good way to bring it all together.

Pam Grant - Risk Management Coordinator
MedStar - Union Memorial

Doug Plucknette

“Very complete course on how to perform RCA from start to finish. Real life examples of problems are excellent in making connections.”

Doug Plucknette
Eastman Kodak

Vernon Kingsbury

Lafarge Corporation (U.S. Region)

From the results that it [Reliability Center’s Basic Failure Analysis (BFA) process] can achieve, I have a difficult time understanding why every company in the U.S. does not make use of BFA as a regular part of the way they conduct business.

Vernon Kingsbury - Maintenance Analyst
Lafarge Corporation (U.S. Region)

K. Erasmus

root cause analysis on linkedin

“Bob is not saying do not use the 5 Why’s either, he is saying consider the “how” or “How Can” before you use the 5 Why’s. Bob’s methodology brings about a whole new perspective and you start to see inter-relationships and dependencies more clearly, which could mean the difference between a “Shallow Cause” and a “Root Cause” in a complex environment.

K. Erasmus - LinkedIn RCA Group

Howard Penrose

howard-penrose

We use We use the PROACT System at MotorDoc LLC for our forensic investigations of electrical system and electric motor failures. I’ve used it to solve management issues, long-term machine conditions and more for well over a decade. We highly recommend the system and process – it works! I’ve staked my reputation on it many times with absolute confidence.

Howard Penrose - PhD, CMRP
Howard Penrose

Paul Andrews

Cliffs Natural Resources

Your work (Reliability Center) has helped Cliffs Natural Resources to learn from their failures. The training and consulting in root cause analysis (RCA) has helped Cliffs pinpoint the underlying reasons for problems and paved the way to develop strategies for improving performance.  Your (RCI) efforts have allowed Cliffs to have significant and widespread financial benefits. These efforts have specifically resulted in improved production, increased maintenance precision and improved business focus.

Paul Andrews - Reliability Engineer
Cliffs Natural Resources

Anne Flood

MedStar Union Memorial Hospital

We have gotten so much more from our analysis using PROACT. What was usually a long drawn out process has been significantly streamlined. Using the program has been a great educational tool for our organization from the clinical side to hospital information system analysis to maintenance engineering.

Anne Flood - Director Risk/Quality
Union Memorial Hospital/MedStar