Undesirable outcomes, chronic failure, incidents, and accidents… The cost of such events to corporations is high, generally adding up to tens and hundreds of millions of dollars in "accepted" losses. Why accept these losses? What if you could understand why these errors occur and eliminate chronic events from occurring altogether? Root Cause Analysis: Improving Performance for Bottom-Line Results, Second Edition shows how to identify, understand, and prevent chronic problems that hinder the attainment of organizational goals using Root Cause Analysis (RCA). The PROACT software, voted "Product of the Year" by Plant Engineering Magazine, and the steps outlined in this text teach you how to automate the RCA process. Used effectively, the information in Root Cause Analysis will improve the reliability of your plant assets and save your company precious time and money.
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Introduction to Root Cause Analysis
Failure Classification
Problems vs. Opportunities
Chronic vs. Sporadic Events
Creating the Environment to Succeed
The Role of the Champion
The Role of the Driver
The Role of the Analyst
Modified Failure Modes and Effects Analysis
The Manual Approach
Enterprise Reliability Management System (ERMS)
The Automated Approach
Preserving Event Data
The Error-Change Phenomenon
Data Collection Strategies for Chronic Events
Data Collection Strategies for Sporadic Events
Ordering the Analysis Team
The Ideal RCA Facilitator
The Ideal RCA Team Members
Their Roles
Analyzing the Data
Defining the TOP BOX
Developing Hypotheses
Validating Hypotheses
Identifying Physical, Human and Latent Root Causes
Communicating Recommendations & Findings
Developing, Prioritizing and Selling Recommendations
The Final Report
The Final Presentation
Tracking For Bottom-Line Results
Developing Tracking Metrics
Exploiting Successes
Creating the "Critical Mass"
Automating Root Cause Analysis
Introducing PROACT V2.0 Software
The Role of RCA in a CMMS Environment
Root Cause Analysis Case Histories
ISPAT Inland, Inc.
Eastman Chemical Company (Kingsport, TN)
LYONDELL-CITGO Refining
Eastman Chemical Company (Worldwide Customer Focus)
Alabama Power Company
Weyerhaeuser Company
Bibliography
Index
Book by Robert J Latino Kenneth Latino
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