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
Reliability Center, Inc. 2000

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
Reliability Center, Inc. 2000

Introduction
Average Returns On Investment

600 - 1000%
"In essence, RCA
is FREE!!!"
Reliability Center, Inc. 2000

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

Reliability Center, Inc. 2000

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

Reliability Center, Inc. 2000

Failure Modes & Effects Analysis

Determining the "Significant Few"
% of Loss

Failure Events

60%

RCA

50%

Root Cause

PSM

40%

for Continuous Improvement

Analysis 30%
20%
10%
0%

80% of loss

- Problem Solving Methods

20% of loss

Reliability Center, Inc. 2000

Two-Track RCA Approach

RCA
Methods
Events

Principal Analyst
Required
Involves All Levels
Part Time/Full Time

Root Cause Analysis

Extremely Disciplined/High
Attention to Detail

Significant Few - 80% of Losses

Random Many - 20% of Losses

PSM

Hourly/Supervisory
Level
Part Time

Reliability Center, Inc. 2000

100% Coverage

Problem Solving Skills

Less Attention to Detail

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
Reliability Center, Inc. 2000

Introduction
PROACT Methodology

Failure Modes & Effects Analysis

The RCA Process

PReserve Event Data

Order
Analyze
Communicate Findings & Recommendations
Tracking the Results

Reliability Center, Inc. 2000

PReserving Event Data You Need to ...

Reliability Center, Inc. 2000

PReserving Event Information

Five Types of Event Data

Parts
Position
People
Paradigms
Paper
Reliability Center, Inc. 2000

The 5 P's

Ordering the Analysis

RCA Project Flowchart
Develop team charter,
critical success factors,
start/end dates

Develop 5 P's and data

collection assignments

Begin logic tree and assign

verifications to team
members (reiterate as
needed)
Develop recommendations
and action plans

Reliability Center, Inc. 2000

Write report and make final

presentation

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
Reliability Center, Inc. 2000

Three Levels of Cause

This is where
most asset
management
programs stop!

Failure
Analysis

Physical Roots

"Witch
Hunting"

Human Roots

RCA

Latent Roots

Reliability Center, Inc. 2000

Component Causes

Inappropriate Human Intervention

Deficiencies in Management Systems

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

Reliability Center, Inc. 2000

Tracking for Results

As Proaction Increases...

Production Increases

Growth & Security

Increases
Reliability Center, Inc. 2000

Profits Increases

Root Cause Analysis System

PROACT Software

Plant Engineering Magazine

1998 Gold Award Winner
General & Maintenance Software
Reliability Center, Inc. 2000

Root Cause Analysis System

VERSION 3

Reliability Center, Inc. 2000

The PROACT System

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

Reliability Center, Inc. 2000

PReserving Event Data

The 5 Ps
Team
Member

File
Linking

Reliability Center, Inc. 2000

Ordering the Analysis Team

Easily
Assign
Members
Team Pool

Quickly Set
Permissions
by RightClicking
Reliability Center, Inc. 2000

Analyzing Event Data

Drag/Drop
Logic Tree
Logic Tree
Icons
Presentation
Mode

Reliability Center, Inc. 2000

Communicating Findings &

Recommendations
Table of Contents
I. Executive Summary
Description of Failure Event
Description of Failure
Mechanism
Overview of PROACT
methodology
Root Cause Action Matrix

II. Detailed/Study Section

Detailed Recommendations

III. Appendices

Recognition of Participant Involved

Reliability Center, Inc. 2000

Additional (Optional)

5 Ps Data Collection Forms

Team Member Data
Team Charter
Team CSFs
Team Start/End Dates
Verification Log
Logic Tree

Communicating Findings &

Recommendations
Custom Report
Writer

Reliability Center, Inc. 2000

Tracking For Bottom Line

Results
Chart Wizard

Reliability Center, Inc. 2000

PROACT Training
PROACT Software Training
Day) - For PROACT Users

(1-

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

www.reliability.com
Reliability Center, Inc. 2000

Whats The Organizations Objective?

Asia
Enterpri
se
Version
Desktop
Version

Latin America
VS Enterpri
se
Version

Europe
Server

Enterpri
se
Version

USA
Single-User

Reliability Center, Inc. 2000

Enterpri
se
Version

Network (SQL/ORACLE)

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
Reliability Center, Inc. 2000

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

Reliability Center, Inc. 2000

Root Cause Analysis Methods for

Principal Analysts (3-Days) - For
Team Leaders (A.C.R.)
PROACT Software Training
Day) - For PROACT Users

(1-

Where Do
We Go
From
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

Reliability Center, Inc. 2000