ASQ Root Cause Analysis Corrective /Prevention Action (CAPA)

Introduction

Solving problems and implementing improvements doesn’t happen by chance: it requires a thorough and methodical processes and tools to identify, solve, and prevent problems at the root―often missing from business or engineering school programs. With this modern and engaging Root Cause Analysis live face-to-face course from ASQ, you will learn how to systematically eliminate errors by rooting them out, leading your team and your business to reduced risks (like recalls), increased safety practices, and improved margins and operations. Take part in engaging sessions with fellow learning professionals, and gain new practical knowledge alongside new networking opportunities. As an organization, face-to-face training means no disruption to your team and operations, with maximum engagement whenever and wherever you need them. This extensive class provides delegates abroad coverage of Root Cause Analysis and Correct Action-Preventive Action (CAPA) technique and tools. The purpose of this course is to provide delegates with the knowledge and skills necessary to facilitate an effective problem-solving analysis. The training introduces delegates to problem-solving methodology, demonstrating how you can select and apply the most appropriate tools and techniques to investigate and solve a variety of problems. Root Cause Analysis (RCA) is a method of problem-solving used to identify the root causes of faults, failures or problems which can enable professionals in your organization to identify the reasons why things go wrong and address the issues when customers complain about products and services. RCA & CAPA encompass a wide range of approaches, tools, and techniques which enable problem-solving teams to look deeper into problems, uncover causes and suggest possible solutions, allowing you to prevent and control chronic and recurring problems by eliminating or detecting the causes of failure in your product design, production processes and administrative systems. During the course delegates will be able to implement RCA & CAPA methodologies to address concerns including:

• Product failures
• Process failures and poor product quality (defects)
• Poor process flow and productivity
• Cost of poor events and rework

Addressing the root causes of problems improves quality, process flow, and productivity while also improving staff morale as employees become engaged and empowered in the creative process of problem-solving and process improvement at all levels of the organization. 

Objectives

• Understand RCA terminology, goals, benefits, and stakeholders.
• Investigate root causes with cause-and-effect analysis, 5 Whys, FMEA, and other analytical tools.
• Assess and work with various data collection plans and methods, as well as data charts and control charts.
• Define problem-solving models used for root cause analysis, including 8D, PDCA, and DMAIC. Implement problem-solving techniques (poka-yoke, multi-voting, etc.) and plan, manage, and verify change.
• Build and manage RCA project teams successfully.

Training Methodology

The interactive program utilizes different methods, such as examples, practical exercises, case studies that enable participants to apply the concepts and methods learned in their actual environment. In each module, participants will review industry related examples & a variety of tools used in respective module topics; interactive group practical exercise/scenario to apply the learned concepts on real-life situations from the work environment. At the end of the program, the evaluation will incorporate lessons learned.

Who Should Attend?

This Root Cause Analysis live in-person course by ASQ is relevant for any quality professional, and contains practical and relevant examples for all industries―with special consideration given to manufacturing and engineering. Anyone with a desire to improve problem solving in their organization can take this course, regardless of their role or experience.

• Managers responsible for the process and quality improvements
• Quality Managers, Internal and External Auditors
• Line managers and supervisors involved in managing customer and/or supplier relationships
• Problem-solving team members and leaders
• Product or process designers
• Industrial, production, and process engineers

Course Outline

Identification of Problem Types/Processes

• Reactive
• Proactive
• Prioritization
• Roles and Responsibilities
• Problem Definition – What/When/Where

Objectives and Success Measures

• Scope/constraints
• Causes and Time Lines
• Costs – impact and resolution
• Measuring the problem

Root Cause Analysis Process

• Logical analysis
• Data Analysis
• Ishikawa diagrams
• 5 Whys Application
• Root Cause Hypothesis
• Cause-Mapping techniques

Corrective Action – Preventive Action Process

• Root cause verification
• Developing a selected solution
• Risk analysis
• Error-Proofing methods
• Failure Mode and Effects Analysis (general coverage)
• Implementation planning process and tools