Does a Root Cause Exist?

Root Cause Analysis or RCA is an incredible tool for improving your operation or processes, but there are a few points that "practitioners" sometimes miss. One of which is that there is very seldom one root cause...in fact in most cases there are at least two. One is a condition that has existed for some period of time and the other is an action that allowed the condition to create an undesirable outcome. Lets look at a very simple example, if you slip on a wet floor there was a condition (the wet floor) and an action (you stepping on the wet floor). If you think about it this way, then you can decide which cause to eliminate. You can eliminate the water causing the wet floor or the action of walking through it.  Of course, you should dig deeper into each of these branches to better understand the underlying causes but this works for a simple example. The point is when you neglect one of these elements you limit your ability to mitigate or eliminate the failure at the lowest cost. Sometimes the condition or action will appear blatantly obvious but remember that even though it is obvious we list it to ensure that we consider its elimination or modification as a possible solution. I have witnessed many sites using the 5 Why methodology which typically leads to one "root cause" and in many cases the solution is more expensive and more complicated than it need be.  I like the 5Why methodology for building a root cause culture in your facility, but it should not be the back bone of your Root Cause Analysis program. So does root cause exist? Only if you consider root causes.

You Might Not Have a Program....

Below is a list of things Andy Page and I have seen and heard over the years that might make you laugh but should make us cry when it comes to having a solid reliability program.

If you think change management has something to do with the vending machines in the break room ...you might not have a program

If you think change management means always having a roll of quarters in your desk...you might not have a program

If your alignment standard contains the words flashlight and straight edge...you might not have a program

If your scheduling meeting usually end with the phrase “I guess we’ll just see about that”...you might not have a program

If your job plans can all fit on 1 side of 1 piece of paper...you might not have a program

If the phrases inner race and outer race remind you call your bookie...

If the phrase ball pass frequency just makes you giggle uncontrollably...

If your IR electrical program is administered by your insurance provider...

If you can name all of the machines on your oil sampling route...

If every time the 6 Sigma guys talk about the 16 Toll Gates to improvement and you wonder why they just didn’t take the back roads...

If you think precision maintenance means having a complete set of hammers with you at all times...

If you think torque wrenches are only for the boys of NASCAR...

If your balance standard involves the use of a nickel or a small glass of water...

If you measure your lubrication quantities in tubes…

If your idea of contamination control has something to do with keeping the rats out of the break room…

If you think the planner should have his own set of tools…

If you think that every mechanic should have his own key to the storeroom…

If you think a dial indicator is a new option on your son’s cell phone...

If your idea of a shim pack includes the cardboard box the pump came in ...

If your idea of a battery tester includes the use of the tip of your tongue..

If you think eddy currents are something you have to avoid at the beach...

If your most advance machine analysis tool is a screwdriver held against your ear...

If your torque standard involves Bubba and a cheater bar...

If your X-ray equipment was ordered from the back of a comic book...

If your machine base grouting procedure includes the use of bubble gum and chap stick...

If your maintenance reference library includes only two service catalogs, one handbook and yesterdays paper...

If your Root Cause Analysis process includes a step for dumpster diving...

If your required PPE includes a bubble wrap suit...

If your folks believe that TPM stands for Totally Painted Machines...

If you repair the same equipment so often you have a special cart...

If your ultra sensitive leak detection system involves an funnel held up to Eddie's ear...

If your Root Cause Analysis findings include “fire the SOB”...

If your idea of a bearing heater is a rose bud…

If your idea of proper bearing installation involves a hammer and a chisel…

If your lubrication guy still believes that more is better…

If the closest thing to RCM you have is Rapid Corrective Maintenance...

Hope you enjoyed those and if you can, take a minute and add a few that you have heard or seen at your site.

Seven Rules for Free MRO Vendor Provided Training

Free or almost free training” Ah the holy training grail we have been looking for. Does it work? Sure if you spend the time up front to build it into your plan and have clear expectations for what it can and can not do. I suggest it not be used as your core craftman skills training, but it works great as a refresher courses. Chances are you company’s preferred vendors will provide training on anything from belt installation to lubrication practices. We also had some experience with smaller regional vendors such as nut and bolt suppliers. They can help with proper fastener application and torque as an example. The only drawback is that you must really pay attention to the material that the vendor wants to present to avoid too much sales propaganda. I have used many different vendors for this type of training and I have only had one that turned out to be there for a sales pitch. Using the seven rules below we caught this before wasting the craft’s time in the session. The seven keys to success with the vendors training includes the following:

1.  Try to have the vendor bring in their technical people and not just the sales guy.

2.  Make it clear that the maintenance staff is not the purchasing department and a whole lot of sales hype will be futile.

3.  Ask the vendor if he has done sessions like this before.

4.  Review agenda ahead of time and suggest topics of interest to your group.

5.  Always give the vendor a tour of the plant prior to the presentation so that he can speak to the types of equipment that you have and the problems you face.

6. Make sure you talk with the presenter ahead of time to make sure he has a certain level of charisma and presentation skills or bring pillows for the sleeping technicians.

7.  If you are worried about a vendor then have them do two sessions the same day and you and a few others attend the first session before committing a larger portion of the maintenance group to the second one.

            Free training can work to satisfy many of the basic training needs especially refreshers that are required to keep us competitive as long as just like any other part of your training program you put in the work up front.