Root Cause Analysis (RCA) is a one - day course that balances lecture and a series of workshops that participants get to learn how to use the tools of RCA by actually using them. The course begins by focusing on team skills such as brainstorming and developing consensus on teh statement of the problem. Then we work through eight common tools used to find root causes of problems with either fabricated or real scenarios to allow meaningful workshop examples. We close the course by examining issues and concerns related to implementing a system to manage root cause analysis.Course outline
Key Course Objectives
- Introduction and Team Work
- Statement of the Problem
- Process Flow Charts
- Process Models
- 5 Whys
- Cause and Effects Analysis
- Statement of the Problem Revisited
- Change Analysis
- Barrier Analysis
- Events and Causal Factors Analysis
- Fault Tree and Success Tree Analysis
- Implementing Root Cause Analysis
- To explore ISO 9001 and IATF 16949 requirements for root cause analysis.
- To understand and use the Plan-Do-Check-Act cycle (PDCA) for problem solving.
- To provide a structured approach to develop a problem statement.
- To introduce and give experience in the use of root cause analysis tools.
- To assess solutions for their impact on cost and hiring.
- To document the knowledge gained from root cause analysis.
- To consider what can cause the process of root cause analysis to fail.
Mark A. Morris was elected an American Society for Quality Fellow in 2013. Mark has taught in seven countries and in 22 of the United States. He has work experience in tooling and manufacturing as a machinist, toolmaker, gage builder, college instructor, technical writer, and quality professional in roles from Quality Engineer to Manager of Quality Planning to Director of Continuous Improvement. His expertise lies in quality engineering, dimensional management, reliability, maintainability, and quality systems. Credentials include undergraduate degrees in manufacturing engineering technology, industrial education, and metalworking; Master of Education degree from the College of Technology at Bowling Green State University; Certified Quality Engineer (CQE), Certified Reliability Engineer (CRE), and Certified Quality Auditor (CQA) certifications from the American Society for Quality; and Senior Level Geometric Dimensioning and Tolerancing Professional (GDTP) certification from teh American Society of Mechanical Engineers. Mr Morris is an ASQ Validated Instructor with the ASQ Learning Institute. He presently serves as Deputy Regional Director for ASQ Region 10 and Chair Elect for the Ann Arbor chapter fo Society of Manufacturing Engineers (SME).