Root Cause Analysis: 5-Day Professional Training Course

Course Overview

This comprehensive Root Cause Analysis Training provides systematic methodologies for identifying and eliminating underlying causes of problems, failures, and incidents. This intensive 5-day program covers RCA fundamentals, problem-solving techniques, investigation methods, data analysis tools, corrective action development, and implementation strategies for quality, safety, maintenance, and operations professionals across industries.

Who Should Attend This Root Cause Analysis Course?

• Quality Engineers investigating product defects

• Maintenance Engineers analyzing equipment failures

• Safety Officers investigating incidents and accidents

• Operations Managers solving process problems

• Continuous Improvement Specialists leading Lean/Six Sigma

• Plant Engineers reducing downtime and losses

• Reliability Engineers improving asset performance

• Process Engineers eliminating chronic issues

• Supervisors and Team Leaders managing problem resolution

Course Objectives

Participants will master root cause analysis methodologies, problem definition and scoping, data collection techniques, 5 Whys and Fishbone analysis, Fault Tree Analysis (FTA), Failure Mode and Effects Analysis (FMEA), corrective action development, implementation planning, and verification of effectiveness.

Day 1: RCA Fundamentals and Problem Definition

Morning Session: Introduction to Root Cause Analysis

Topics Covered:

• Root cause analysis definition and purpose

• Symptoms vs. root causes distinction

• Reactive vs. proactive problem solving

• Business impact: cost of poor quality, downtime, safety

• RCA methodologies overview: 5 Whys, Fishbone, Fault Tree, FMEA

• When to use RCA: triggers and selection criteria

• Common pitfalls and barriers to effective RCA

• Organizational culture for problem solving

RCA Success Factors:

• Management commitment and support

• Cross-functional team involvement

• Data-driven decision making

• Focus on process, not people

• Systematic methodology application

• Follow-through on corrective actions

Afternoon Session: Problem Definition and Scoping

Topics Covered:

• Problem statement development

• SMART criteria: Specific, Measurable, Achievable, Relevant, Time-bound

• Problem vs. opportunity framing

• Scope definition and boundaries

• Stakeholder identification and engagement

• Impact assessment: safety, quality, cost, productivity

• Prioritization using risk matrices

• Project charter development for major RCA efforts

Problem Definition Tools:

• Is/Is Not analysis for problem clarification

• Problem statement templates

• Pareto analysis for prioritization

• Cost-Benefit analysis for RCA justification

Workshop:
Developing clear problem statements for real organizational issues.

Day 2: Data Collection and Basic RCA Tools

Morning Session: Data Collection Methods

Topics Covered:

• Data collection planning and strategies

• Types of data: quantitative vs. qualitative

• Historical data review and trending

• Physical evidence collection and preservation

• Interviews and witness statements

• Observation techniques and gemba walks

• Document review: procedures, logs, maintenance records

• Photography and video documentation

• Data validation and reliability assessment

Data Analysis Techniques:

• Statistical process control charts

• Trend analysis and pattern recognition

• Timeline construction for events

• Process mapping and flowcharting

Afternoon Session: 5 Whys and Fishbone Diagrams

Topics Covered:

• 5 Whys methodology fundamentals

• Asking effective “why” questions

• Avoiding premature conclusions

• Moving beyond human error to system causes

• Documenting 5 Whys analysis

• Fishbone Diagram (Ishikawa) construction

• Major cause categories: Man, Machine, Method, Material, Environment, Measurement (6Ms)

• Brainstorming effective use in RCA

• Combining 5 Whys with Fishbone analysis

Practical Application:

• Identifying physical, human, and organizational root causes

• Distinguishing causal factors from root causes

• Verification of identified causes

• Documenting cause-and-effect relationships

Hands-On Exercise:
Conducting 5 Whys and creating Fishbone diagrams for case study problems.

Day 3: Advanced RCA Methodologies

Morning Session: Fault Tree Analysis (FTA)

Topics Covered:

• Fault Tree Analysis fundamentals

• Top event definition and decomposition

• Logic gates: AND, OR, NOT gates

• Basic events and intermediate events

• Probability calculations for fault paths

• Minimal cut sets identification

• Qualitative vs. quantitative FTA

• Common cause failures and human factors

FTA Applications:

• Safety incident investigation

• Equipment failure analysis

• Process upset analysis

• Risk assessment and prevention

Afternoon Session: Failure Mode and Effects Analysis (FMEA)

Topics Covered:

• FMEA types: Design FMEA, Process FMEA, Equipment FMEA

• FMEA process and team formation

• Function identification and failure modes

• Effects and severity ratings (1-10 scale)

• Occurrence and detection ratings

• Risk Priority Number (RPN) calculation

• Action priority and corrective measures

• FMEA updates and living documents

FMEA Workflow:

• System/process breakdown

• Failure mode identification for each component/step

• Cause analysis for each failure mode

• Current controls evaluation

• Risk prioritization and action planning

Workshop:
Developing FMEA for manufacturing process or equipment system.

Day 4: Specialized RCA Techniques and Human Factors

Morning Session: Additional RCA Tools

Topics Covered:

• Pareto Analysis (80/20 rule) for problem prioritization

• Scatter diagrams for correlation analysis

• Control charts for variation analysis

• Barrier Analysis for safety and containment failures

• Change Analysis comparing normal vs. abnormal conditions

• Events and Causal Factors Analysis (ECFA)

• Apollo RCA methodology

• TapRooT® system overview

Comparative Analysis:

• Selecting appropriate RCA method for problem type

• Combining multiple techniques

• Simple vs. complex problem approaches

• Resource allocation for RCA efforts

Afternoon Session: Human Factors and Organizational Causes

Topics Covered:

• Human error types: slips, lapses, mistakes, violations

• Human performance factors: fatigue, distraction, time pressure

• Organizational root causes: inadequate procedures, training gaps, poor design

• Latent conditions vs. active failures

• James Reason’s Swiss Cheese Model

• Safety culture assessment

• Just culture vs. blame culture

• Human Factors Analysis and Classification System (HFACS)

System Thinking:

• Moving beyond individual blame

• Identifying organizational weaknesses

• Procedure adequacy evaluation

• Training effectiveness assessment

• Design deficiencies recognition

• Management system failures

Case Study:
Analyzing major industrial accident using human factors and organizational perspectives.

Day 5: Corrective Actions and Implementation

Morning Session: Developing Effective Corrective Actions

Topics Covered:

• Corrective action hierarchy: elimination, substitution, engineering controls, administrative, PPE

• Interim vs. permanent corrective actions

• Action plan development and SMART goals

• Responsibility assignment and ownership

• Resource requirements and budget planning

• Implementation timeline and milestones

• Risk assessment of proposed solutions

• Balancing effectiveness with feasibility

Corrective Action Types:

• Design modifications and engineering changes

• Procedure updates and clarifications

• Training and competency development

• Equipment upgrades and maintenance improvements

• System and process redesign

• Organizational changes and policies

Afternoon Session: Implementation and Verification

Topics Covered:

• Implementation planning and change management

• Communication strategies for stakeholders

• Training and awareness programs

• Monitoring and measurement plans

• Verification of effectiveness criteria

• Leading vs. lagging indicators

• Pilot testing and phased rollout

• Documentation and knowledge management

• Lessons learned capture and sharing

Sustainability:

• Preventing problem recurrence

• Standardization of improvements

• Auditing and compliance verification

• Continuous monitoring systems

• Feedback loops and adjustment mechanisms

RCA Report Writing:

• Executive summary development

• Problem description and timeline

• Analysis methodology explanation

• Root cause findings presentation

• Corrective action recommendations

• Implementation plan and metrics

• Visual aids and supporting evidence

• Effective communication to management

Best Practices:

• Building organizational RCA capability

• RCA database and knowledge repository

• Metrics for RCA program effectiveness

• Integration with continuous improvement initiatives

• RCA team facilitation skills

• Overcoming resistance to change

Final Project and Assessment

Comprehensive RCA Project:
Conduct complete root cause analysis including:

• Problem statement and scope definition

• Data collection and evidence gathering

• Application of multiple RCA tools (5 Whys, Fishbone, FTA or FMEA)

• Root cause identification and verification

• Corrective action development with hierarchy

• Implementation plan with timeline and resources

• Effectiveness verification metrics

• Professional RCA report preparation

• Presentation to management simulation

Assessment Activities:

• Written examination on RCA methodologies and tools

• Practical exercise: facilitating RCA team session

• Case study analysis with tool application

• Group presentation: complete RCA investigation

• Report writing evaluation

• Facilitation skills demonstration

• Certificate of Professional Training in Root Cause Analysis

Course Benefits and Learning Outcomes

Participants will define problems systematically, collect and analyze relevant data, apply multiple RCA methodologies, facilitate cross-functional investigations, identify true root causes, develop effective corrective actions, implement solutions, verify effectiveness, and build organizational problem-solving capability.

Training Methodology

Instructor-led sessions with extensive case studies, hands-on tool application, group problem-solving exercises, facilitation practice, real-world examples from multiple industries, interactive workshops, and project-based learning.

Course Materials

Comprehensive RCA handbook, methodology flowcharts and templates, 5 Whys worksheets, Fishbone diagram templates, FMEA forms, FTA software tools, corrective action planning templates, report writing guides, and professional certificate.

Software and Tools

Introduction to RCA software platforms, Microsoft Visio for diagrams, Excel templates for data analysis, statistical tools, and collaborative online platforms for team investigations.

Prerequisites

No prior RCA training required, basic understanding of organizational processes helpful, logical thinking and analytical skills, experience with problem-solving beneficial, and willingness to participate in group exercises.

Keywords: root cause analysis training, RCA methodology, problem solving techniques, 5 Whys analysis, Fishbone diagram, Fault Tree Analysis FTA, FMEA training, failure analysis, incident investigation, corrective action, continuous improvement, quality problem solving, equipment failure analysis, safety incident investigation, process improvement, RCA tools, systematic problem solving, causal analysis, defect elimination, reliability improvement