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Root Cause Failure Analysis (RCFA) or Troubleshooting for the
Frontline
You may have been through a Root
Cause Failure Analysis (RCFA) training at some point in your career.
If not, you probably are aware of the basic concept and that there are
many Root Cause Failure Analysis (RCFA) classes available to your plant.
Often, we teach our operators, craftspeople, and supervisors the full
Root Cause Failure Analysis process, but there are no work processes (data
collection, triggers, reporting structure, meeting structure etc) to support
the RCFA in the plant. In some cases there aren’t even time to spend
on RCFA because we are too busy working on break-downs.
If there isn’t much time to work on Root Cause Failure Analysis,
but we want our people to do a better job finding the true cause of the
problems, what do we do?
Our suggestion is to teach your “frontline” (operators, craftspeople
and supervision) basic trouble shooting. You may argue that troubleshooting
doesn’t always get to the true root cause and that troubleshooting
doesn’t cover all bases. You are right. Structured troubleshooting
will get to the true root cause 80% of the time with 10% of the effort
a root cause failure analysis (RCFA) takes. Sounds like a good deal, it
is!
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