Reliability Center, Inc. PROACT RCA Procedure

Transcription

1 1. PURPOSE 1.1 To provide consistency to the organization in the application of PROACT Root Cause Analysis (RCA) Process. 1.2 To provide guidance in the following areas: Requests Analyses Reporting Presenting Tracking 2. APPLICATION/SCOPE This procedure applies to all users of the PROACT process conducted in compliance with all Safety Policies and Procedures unless otherwise directed by the Department Manager. 3. RESPONSIBILITY 3.1 The Supervisor of Reliability Engineering (or equivalent) shall have the responsibility to review, amend and revise this procedure as necessary to insure its integrity and application. 3.2 The Supervisor of Reliability Engineering (or equivalent) shall have the responsibility to develop, implement, review, and revise related procedures and/or documents required in this procedure. 4. DEFINITIONS 4.1 Champion: usually a person in authority that sponsors and mentors the Principal Analysts. 4.2 Charter: defines the charter of the RCA effort. 4.3 Chronic Events: events that occur repetitiously. 4.4 Critical Success Factor (CSF): Identifiable marker that will signal the RCA effort has been successful. 4.5 Failure Modes and Effects Analysis (FMEA)/Modified: a technique to identify the most important failures to analyze. 4.6 Logic Tree: a graphical representation of logic used to derive root causes. 4.7 Principal Analyst (PA), Qualified: the individual assigned the responsibility of leading and completing the RCA. The individual is qualified based on their successful completion of Reliability Center, Inc. s (RCI) RCA 3-Day Methods Course. 4.8 PROACT : a software program that facilitates the RCA process. 4.9 Root Cause Analysis (RCA): a disciplined methodology that advocates analyzing events down to their latent root causes, that is, the deficiencies in management systems and restraining cultural norms that allowed the event to occur Significant Few: the 20% of the failure events that have been deemed to be accountable for 80% of the loss. This information is derived from the FMEA Sporadic Event: a one time catastrophic event Vital Many: the many deviations that occur in a manufacturing facility that equate to continuous improvement efforts.

2 5 REFERENCES 5.1 Plant Policy Manual 5.2 Plant Safety Manual 5.3 Plant Quality Manual 6 SPORADIC EVENTS 6.1 A RCA is requested for sporadic events with a total cost (maintenance, operations and lost profit opportunities) greater than $100,000. Listed below are several examples: Unpredicted Event Property Damage Lost Production 6.2 A RCA is requested for sporadic events that result in an OSHA recordable injury or are deemed a safety incident. 6.3 A RCA is requested for sporadic events that are reported to the Quality Organization via customer complaints. 7 SIGNIFICANT FEW A Qualified PA will lead the RCA of the Significant Few events that were identified by the Department FMEA unless redirected by the Reliability Coordinator and/or the Department Manager. 7.1 Assignment of Champion: The Division Reliability Coordinator will be assigned as the Champion of the event that falls within their Division A Qualified Principal Analyst (PA) will be assigned as the PA for the Significant Few events that are assigned to the Department. 8 VITAL MANY/CONTINUOUS IMPROVEMENT The RCA of the Vital Many events will be led by a PA or other qualified personnel that are not in the Reliability Engineering group. 8.1 Assignment of Champion: The Division Reliability Coordinator will be assigned as the Champion of the event that falls within their Division A PA or other qualified personnel will be assigned or obtained by the Division Reliability Coordinator to lead the RCA The Division Reliability Coordinator's role is to provide the resources or obtain the resources that the PA needs to do the job right and to identify and remove obstacles that hinder their analysis.

3 9 DETERMINATION OF TEAM MEMBERS Certain events will require a team to be formed while others will not. If a team needs to be assembled the PA will make a recommendation to the Division Reliability Coordinator. The following items also need to be addressed when selecting the team. Multi-disciplined (i.e. mechanical, electrical, financial, managerial, hourly, etc.) Personnel Directly Affected by Problem or Event Personnel Who May be Involved with Implementation of Solution Excused from Normal Work Assignments While Working on RCA (Similar to HAZOP Studies) 10 RCA METHODOLOGY 10.1 When a team has been formed that is not familiar with RCA, the team will attend, at a minimum, RCI s one day Problem Solving Methods (PSM) course before proceeding with the analysis The team will accurately define the event The Charter and Critical Success Factors (CSF's) of the analysis need to be developed so that each team member knows the purpose of the analysis effort and if the effort is successful Develop Strategy for Collecting the 5 P's. The team or PA needs to develop the strategy for capturing the 5 P's. This may involve taking pictures, retrieving data from the operating instrumentation, interviewing personnel, etc. The urgency that this data is collected will depend upon whether this is a chronic or sporadic event Assignment of 5 P's: The PA will assign the 5 P's (listed below) to team members who will be responsible for collecting the data. Parts Position People Paradigms Paper 10.6 Analyze: Using the data collected, develop a logic tree The Logic Tree will not be considered complete unless the latent roots are identified Hypothesis Verification: Each hypothesis block on the logic tree needs to be verified (proven or disproven). This is one of the most crucial steps in the RCA process. Without verification, the findings and recommendations of the RCA are meaningless.

4 10.8 RE Review Logic Tree: The PA will contact the Division Reliability Coordinator when the team is ready to review the logic tree. The review should take place before proceeding with the report and the formal publishing of the analysis in the PROACT Software Program Write Report: The report should include the following sections: Executive Summary Description of Event Description of Mechanism Review of Causes and Recommendations Assignment of Responsibilities and Time Lines Study Section Detailed Recommendations Appendices Participants Involved 5 P's Forms Verification Logs Logic Tree Develop Draft Recommendations: a presentation of the findings of the RCA shall be given to personnel affected by implementing the recommendations and to personnel who will implement the recommendations and others as applicable. This will provide input that may affect or change specifics about the recommendations Revise and review the recommendations as necessary Develop corrective action items for each of the recommendations Formally present findings and recommendations to the Reliability Team and/or appropriate management personnel for implementation approval. 11 UITLIZATION OF PROACT RCA SOFTWARE All documentation of RCA s are to be stored electronically using the PROACT RCA software program on the designated client server. Use of this program shall be in strict accordance with the license to the corporation User Prerequisites: All users of PROACT must first successfully complete requisite training in one or more of the following courses based on their participation in the analysis RCA Methods: All Principal Analysts (PA) shall complete the 3-Day RCA Methods course presented by Reliability Center, Inc. (RCI) either on-site or at a public location. It will be at the discretion of the PA to determine which Team Members receive the password for password protected analyses.

5 PSM (Problem Solving Methods): All RCA team members shall successfully complete the 1-Day PSM training by licensed RCI PROACT Software Training: All users of PROACT RCA software shall successfully complete either the 3-Day RCA Methods training or the 1-Day PSM training before becoming eligible for PROACT training. All potential PROACT users are required to attend a four-hour short course in hands-on PROACT instructor led training The PA shall responsible for the complete accuracy of the analysis utilizing the software program. Team members shall update their responsibilities in any given analysis, however the PA is ultimately responsible for reviewing the accuracy and thoroughness of the complete analysis The PA will assume the responsibility of when it is time to PUBLISH the RCA. Publishing the analysis in PROACT means that the completed RCA is certified to be accurate and thorough. Once published, the analysis serves as a Logic Template for the rest of the corporation. Publishing also means that all sensitive materials have been reviewed by the legal department and have been approved for publishing in this format The PA will reserve the right to password protect the RCA. Only team members of that specific RCA shall be permitted to have the password. It shall be the responsibility of the PA to remove the password once the RCA has been published. 12 CORRECTIVE ACTION AND TRACKING Personnel will be assigned responsibility for the corrective actions necessary to implement the recommendations that result from the RCA. These corrective actions will be tracked and a report issued The Division Reliability Coordinator and PA will assign responsibility for the corrective action items unless otherwise directed by the Department Manager or his designee The PA will notify a member of the Reliability Deployment Projects Group (RDPG) that the RCA corrective action items have been assigned The PA will see that a copy of the full report (hardcopy & electronic) is given to the RDPG for filing purposes RCA's that result from events listed Safety Procedures will primarily be handled by Plant Protection or Environmental Affairs. These Departments are responsible for tracking corrective action items that result from these RCA's All RCA's corrective action items (except as noted in 10.5) will be issued as needed in a report to the personnel assigned responsibility for the items. The corrective action items will remain in the report until completed Updates to the report can be forwarded to the Division Reliability Coordinator as they are completed and will be incorporated into the next quarterly report A progress report will be sent to the Department Manager for his review.