Investigating Equipment Failures Through Root Cause Failure Analysis: 9th Discipline on World Class Maintenance Management - Softcover

Angeles, Rolly

Softcover

ISBN 13: 9798885260015

Publisher: Rolando Santiago Angeles, 2021

Synopsis

People become successful in life by failing. The truth is, we cannot achieve success if we do not fail. Failure is inevitable. It will happen.  Success comes after failure.  Just like in industries, when an equipment failure happens, we need to accept it, challenge it and the most important of all is to learn from the failure.  This means that when an incident happens, we have two options, either we learn from them or just ignore them and let the failure repeat itself.  The message of Root Cause Failure Analysis is simply to take the first option and learn from the failure.  The reason for conducting Root Cause Failure Analysis is for industries to learn from the things that go wrong so that we can prevent it from happening in the future.
 
Although there are many ways and techniques how to analyze the problem, what the author believes is that the root cause can only be derived if the evidence is well preserved.   Without the presence of evidence, one can only speculate, agree, disagree, brainstorm, or make a judgment based on their experience.  A true root cause will separate the facts from fiction before we spend time and resources to finally address the cause of the problem.   Also explained in this book is the difference between conducting a Root Cause Failure Analysis Investigation and the common analytical problem-solving tools.
 
The author of this book based his interpretation on his personal knowledge, experience, and former affiliation with one of the leading providers of Root Cause. I believe that uncovering the root cause is based on 100 % facts and pieces of evidence unfolded.  Any investigation that is not based on evidence will not generate the root cause but only the probable or the most likely cause of the failure. The words Root Cause Analysis (RCA), and Root Cause Failure Analysis (RCFA) will be used respectively in this book. The author would prefer to use the word Root Cause Failure Analysis for equipment-related problems, while Root Cause Analysis will be used for non-equipment-related problems such as accident or safety investigation, quality defects investigation, and administrative incident investigation. Failures must not only be prevented nor predicted but what is important is challenging failures and learning from them. Finally, this book ends on what the real message of Root Cause Failure Analysis is all about.  Some of the highlights of this book include:
 
- Why Failures are Important
- Why MTTR and RCFA are The Opposite of Both Worlds
- The Slow and the Fast Train
- The Golden Rule on Root Cause Failure Analysis
- Is Root Cause Failure Analysis Reactive or Proactive?
- Difference Between Analytical Problem Solving Tools and RCFA
- Evidence: The Lifeblood of Root Cause Failure Analysis
- Three Types of Evidence on RCFA
- Understanding the Physical Cause of Failures
- Understanding Human Errors
- Is It Possible to Eliminate Human Error in Maintenance?
- Classic Case of Human Error - The Sinking of the RMS Titanic
- Ending Our Probe on the Latent Cause of the Problem
- Classic Case of Latent Cause: The Challenger Disaster
- Decoding the Song Man in the Mirror by Michael Jackson
- Detailed Steps in Conducting an RCFA Investigation
- Different Types of Corrective Actions
- Actual RCFA Case Study
- FAQs, Tips, and Donts on RCFA
- All Failures have a Reason for Failing
- The Message of Root Cause Failure Analysis

About this title

About the Author

• Rolly is one of the World Class Best Trainers I have come across during my 28 years career. The course was built up very methodically in the simplest way. His presentation skills and his command of the various Maintenance Strategies made the workshop very interesting. Mr. Rolly is one of the few Maintenance Professionals I have come across, attached, and dedicated to the Maintenance Profession. His wealth of experience and his humor made the RCM Workshop even more interesting. The structuring and delivery of the concept enable all the participants to initiate RCM studies very confidently. The training material provided by Mr. Rolly was excellent and was prepared with great care to ensure that all the participants have fully benefited. I am sure that all the participants in this three-day workshop have benefited from his technical and intellectual sharing of his knowledge. From Srinagesh Dy, General Manager, Reliance Industries Ltd., India

• Rolly Angeles is one of the best trainers (World Class) I have ever met in my life. The delivery of the RCM course by him was so smooth and straight to the point. Besides, he combined technicality with intellectualism, thereby carrying even the most assumed idle time along. The definition of the different tasks in RCM caught most of my attention. The RCM Information Worksheet simplifies the course to enable an ideal team to develop the best maintenance strategies. Although it is challenging to convince the management team that is not trained on RCM to adopt it, I will still insist that RCM is the best maintenance strategy worldwide. From Kalu-Kalu, Head of District Maintenance, Nigeria

From the Back Cover

RSA Reliability and Maintenance Book Series

• World Class Maintenance Management-The 12 Disciplines: Many industries are looking for ways to achieve a World Class Maintenance Management Level. This book details the 12 Disciplines of Maintenance to achieve a level of World Class Maintenance. The book is easy to absorb as it is structured into three parts: the Basics, the Strategies, and the Advance Disciplines. This book aims to address the very basics first before doing the strategies and the more advanced disciplines.

• Maintenance-Roadmap to Reliability: This is a sequel to my first book on World Class Maintenance Management, the 12 Disciplines. This book provides a detailed systematic roadmap for achieving a high level of Reliability for industries' equipment and assets. There is no better way to start the journey to Reliability than to go back to the basics and address the very small problems we have in our plant.

• Reliability-A Shared Responsibility for Operators and Maintenance: This book is a sequel to my first and second book and discusses the importance of having an operator and maintenance partner for industries. The message of this book is simple and straightforward industries cannot escape the vicious cycle of being reactive unless they realize the importance of operators in the reliability strategy. It is time for the separation between operators and maintenance to end and, finally, a partnership. Improving Reliability is not the sole responsibility of the maintenance function.

• Cutting-Edge Maintenance Management Strategies: This book also deals with the different cutting-edge maintenance strategies that industries must adopt to survive their competition. In industries today, the law of the jungle applies, survives, or is left behind. Learn how these strategies can link together in building a solid maintenance structure in the plant.

• Problems and Solutions on MRO Spare Parts and Storeroom: This book cover the most common problems in MRO Spare parts and storeroom and how to deal with each of these problems. One highlight of this book is that it provides the readers with an algorithm or MRO decision diagram to determine what parts to stock or not to stock in their storeroom.

• Lubrication Tactics for Industries Made Simple: An easy-to-read book that provides the different strategies applied to lubricating grease and oil for equipment and assets to lessen lubricants' cost failures attributed to lubrication failures.

• Decoding Reliability-Centered Maintenance for Manufacturing Industries: This is a detailed and easy-to-read book designed for manufacturing industries to successfully implement RCM in their equipment and assets. These industries suffer from failures and breakdown losses as well.

• RSA Reliability and Newsletter Vault Collection: This book is a special collection of this series, which collects the author's maintenance and reliability newsletters compilation, covering a wide range of topics on reliability and maintenance best practices.

• Investigating Equipment Failures Through Root Cause Failure Analysis: People become successful in life by failing. The truth is, we cannot achieve success if we do not fail. Failure is inevitable. It will happen. Success comes after failure. Just like in industries, When an equipment failure happens, we need to accept it, learn from it, challenge it and finally overcome the failure. This means that when an incident happens, we have two options, either we learn from them or just ignore them. The message of Root Cause Failure Analysis is simply to take the first option and learn from the failure. This book may be different from other books on root cause as the thoughts I have written in this book defies the conventional methods and tools for conducting a root cause.

From the Inside Flap

• This book may be different from other books on root cause as the thoughts I have written in this book defies the conventional methods and tools for conducting a root cause. I only learned the true meaning of what root cause is when I attended a training on a 4-day Latent Cause Experience with my friend Bob Nelms from Failsafe Network. Reminiscing the times when I was still employed, we were already conducting what I thought was a Root Cause Analysis on defects and equipment-related failures. I was very wrong on this. My only regret was how I wish that I knew this subject when I was still employed so that we can learn from the lessons of failure. Almost all industries have their own way of performing a root cause for related safety, defects, and failures. My only question is, have we really understood the root cause of our failures, or do the very same causes keep on recurring back? This book will answer what does it take to perform a Root Cause Failure Analysis investigation on failures and incidents in our industry?

• There are many versions, techniques, books, training, and consultants worldwide that explain and teach how to conduct a Root Cause Analysis or Root Cause Failure Analysis. Some of these people who conduct these RCA or RCFA training are either my connections on LinkedIn or even personal friends. In fact, there is no standard or, what we can say, a universal approach on how root cause is and should be done, including in this book. This book may also contradict other books on how to conduct a root cause failure investigation. I am not stating that my method or their method is right or wrong, but rather my point is that the context of this book is based on what I teach and what I believed. I have been employed for many years in different industries, and the word root cause is perhaps a very saturated word. We always discussed the root cause of this when the boss asks about it but only to realize after several years that what we have been doing is not really meant to address the root cause of the problem. Thanks to my good and dear friend Bob Nelm for enlightening me on what a true root cause is all about.

• The author of this book based his interpretation on his personal knowledge, experience, and former affiliation with one of the leading providers of Root Cause. I believe that uncovering the root cause is based on 100 % facts and pieces of evidence unfolded. Any investigation that is not based on evidence will not generate the root cause but only the probable or the most likely cause of the failure.

• The words Root Cause Analysis (RCA), and Root Cause Failure Analysis (RCFA) will be used respectively in this book. The author would prefer to use the word Root Cause Failure Analysis for equipment-related problems, while Root Cause Analysis will be used for non-equipment-related problems such as accident or safety investigation, quality defects investigation, and administrative incident investigation.

Edition details

• Publisher: Rolando Santiago Angeles
• Publication date: 2021
• Language: English
• ISBN 13: 9798885260015
• Binding: Paperback
• Number of pages: 346