Advanced Root Cause Analysis

Summary

The root cause of the issue is something that can be clearly switched off and back on again; and unless this is identified, any changes made will not fix the problem permanently. Once you have identified the root cause, often the solution is straightforward.

We have designed this interactive and intensive two-day course to provide improvement specialists with tools and an effective approach to identify key business issues and their real root causes. We also offer some creative tools to develop options for improvements.

How will I benefit?

After the course you will be able to:

  • Identify the true root causes of complex problems
  • Facilitate RCA activity within teams and lead the practical use of the core tools (Silent Brainstorming, Fishbone, 5 Whys) that will lead to action
  • Apply advanced investigation techniques to analyse incidents and failures
  • Improve problem-solving confidence and decision making by using structured, evidence-based investigation methods.
  • Reduce recurring issues, operational disruptions, and costs by implementing corrective and preventive actions that address underlying causes.
  • Strengthen organisational learning and continuous improvement by documenting findings and embedding lessons learned into processes and systems

Who should attend?

This course is designed for personnel who are responsible for diagnosing, investigating, and preventing complex problems or failures in systems, equipment, or processes. It is particularly suited to:

  • Managers and Team Leaders responsible for driving continuous improvement
  • Mechanical, Electrical, and Process Engineers involved in investigating equipment failures and operational disruptions
  • Maintenance and Reliability personnel seeking methods to analyse recurring faults
  • Quality Engineers, Project Engineers and Continuous Improvement Specialists responsible for identifying the underlying causes of defects, non-conformities, and performance issues
  • Production and Manufacturing Engineers tasked with improving operational performance and preventing recurring production problems

Course Outline / Key Topics

Introduction to Advanced Root Cause Analysis

  • Limitations of basic problem-solving methods
  • Reactive vs proactive analysis
  • Systems thinking and complexity in problem solving

Problem Definition and Scoping

  • Defining the problem statement clearly
  • Identifying stakeholders and impact
  • Establishing investigation boundaries

Data Collection and Evidence Gathering

  • Fact-based investigation techniques
  • Interviewing and observation methods
  • Timeline creation and event mapping

Distinguish correlation from cause (Causal Analysis Tools)

  • Event and causal factor analysis
  • Cause-and-effect matrix

Analytical Techniques

  • Affinity Mapping
  • Advanced fishbone
  • The 5 Whys – advanced application and pitfalls
  • Logic Tree Methods
  • Change Analysis (Is / Is Not)
  • Comparative analysis
  • Possible cause theories

Human and Organisational Factors

  • Human error vs system failure
  • Latent vs active failures
  • Organisational and cultural contributors

Identifying Corrective and Preventive Actions

  • Developing effective solutions
  • Eliminating root causes vs mitigating risk
  • Prioritising actions based on risk and impact

Verification and Validation

  • Testing proposed solutions
  • Monitoring effectiveness
  • Preventing recurrence

Reporting and Communicating Findings

  • Structuring RCA reports
  • Presenting investigation findings to stakeholders
  • Embedding lessons learned into organisational processes