root cause analysis - when is a problem not a problem?

When is a problem not a

problem?Why the problem definition is

critical to an effective Root Cause Analysis

Spending time on the problem definition means the

RealityChart is concise and the time to develop it is less

of a drain

Consider this example

© 2012 ARMS Reliability 2

A forward thinking maintenance manager dedicated two hours, every

two weeks, to run RCA workshops.

The goal?

To understand and resolve the small, niggling, day to day issues.


It was a “show and tell” affair, where the technicians would bring failed items, and the group would try to

implement solutions. They set about it with little structure and a

“problem-solution” mentality.


Eventually the Apollo Root Cause Analysis Process

was implemented to give the sessions some

structure


A big Problem was identified


One of the technicians complained about the dry break couplings used on the tanker

offloading systems

“They want changing, they’re dreadful, and they cost around

£5,000. They fail every month or two and there are four in use on the

plant”.

Ignoring the solution the technician gave, it was a great definition and a

significant problem © 2012 ARMS Reliability 7

Following the Apollo RCA Process we started with the problem definition of

“offloading couplings are dreadful”

We added the where and the when then moved onto the significance.


“Well……..actually…… I’ve started repairing them, rather than

throwing them away”

What does that involve? “I change the ‘O’ rings”

“How much do they cost?” “£10” – low significance, there then!

A failure every 1-2 weeks, how much downtime does the failure cost?


“Well, when it starts getting tight to use, I’ve asked the operator to tell

me and I plan some time with him”

excellent, no real downtime then either!


Presumably the time to repair has some effect on the plant?

“Well….. No, not really, it’s a fairly quick job”


So we needed to find solutions to ‘dreadful

offloading couplings’ trying to save the business £10 per month with no down

time and no significant impact on production?


“Yeah, well…. but they’re still dreadful!”

said the technician.


The rest of the team pointed out that he’d already

investigated it, found robust solutions and implemented

those solutions! All that needed doing was

to communicate the success.


A quick learning slide and the new ‘best practice’ shared

across the site.

“Problem” solved.

You don’t get a more concise RealityChart than that!


Learn more about the Apollo Root Cause Analysis Process

for solving your business problems at

www.apollorootcause.com


http://www.apollorootcause.com/

root cause analysis - when is a problem not a problem?

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