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6 - Root Cause Analysis APPOLO

APPOLO

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mamdouh motea youssef
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331 views6 pages

6 - Root Cause Analysis APPOLO

APPOLO

Uploaded by

mamdouh motea youssef
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 6

EXPERT

INSIGHT

Root Cause Analysis


and Effective
Solutions

Together we can
Co-Create a new Story of your
Asset Reliability and Performance

Whether you need some support to


achieve your goals, a complete
reliability program, training or
something in between.

Your Asset Performance and Reliability


Story can change, we’re ready to lead
you into that future.

Proudly partnering with:


Root Cause Analysis PAGE 2

Root Cause Analysis (RCA) is a problem-solving methodology used to identify


the underlying causes of an issue or problem rather than just addressing the
symptoms. The main goal of RCA is to prevent the problem from recurring by
addressing its root causes.

Many methods focus on identifying the root cause, that's right the notion
that a single root cause exists and eliminating that root cause will prevent the
issue or problem reoccurring.

A poll undertaken in the reliability engineering community indicated that


close to 50% use to the 5-whys. Many people refer to 5-whys as a
methodology, truth is, 5-Whys is a tool and not a method. Even staunch
advocates of the 5-Whys method acknowledge its limitations. Frequently,
those who employ this approach focus solely on one causal chain,
overlooking the fact that accidents and problems rarely stem from a single
cause. Consequently, they only scratch the surface, analysing merely a
fraction of the complex issues that demand resolution.

Apollo Root Cause Analysis challenges the notion that causation is linear.
The method challenge the idea, that we are seeking Root Causes, but rather
to determine effective solutions to the issue or the problem. Let's challenge
the idea that there is a single root cause to each issue or problem.

Apollo Root Cause Analysis is becoming the standard for all event analysis
because it is the only process that understands and follows the cause-and-
effect principles, thus it is the only process that allows all stakeholders to
create a clear and common reality to promote effective solutions every time.

Still not convinced? Lets looks at a practical example where a problem is


analysed using 5-Whys and Apollo Root Cause Analysis.
Pump Failure Example (5-Whys) PAGE 3

Problem: The pump has failed, leading to a disruption in the fluid flow
causing significant production delays.

Let's use the 5-whys Tool

1. Why did the pump fail?


Because the pump motor burned out.
2. Why did the pump motor burn out?
Because the motor was drawing excessive current.
3. Why was the motor drawing excessive current?
Because the pump's impeller was clogged with debris and causing
increased resistance to rotation.
4. Why was the impeller clogged with debris?
Because the maintenance schedule for pump inspection and cleaning
was not followed regularly, allowing debris to accumulate over time.
5. Why was the maintenance schedule not followed regularly?
Because there was no proper maintenance tracking system in place,
and maintenance tasks were not adequately prioritized or assigned to
responsible personnel.

Root Cause: The pump failure occurred due to a combination of factors: the
impeller getting clogged with debris and the motor burning out as a result of
excessive current draw. These issues, in turn, were caused by a lack of regular
pump maintenance, inspection, and cleaning, which was further exacerbated
by the absence of an effective maintenance tracking system.

Corrective Actions:
1. Conduct immediate maintenance on the pump, cleaning the impeller, and
repairing or replacing the burned-out motor.
2. Implement a regular maintenance schedule and ensure that pump
inspection and cleaning tasks are performed at appropriate intervals.
3. Train staff on the importance of adhering to the maintenance schedule
and provide resources to support proper maintenance practices.
4. Periodically review and improve the maintenance procedures to prevent
future pump failures and enhance the reliability of the pump system.
Pump Failure Example (Apollo) PAGE 4

Let's use the Apollo Root Cause Analysis Methodology for the pump failure
using the four steps detailed below.

Step 1: Define the Problem


Develop a common understanding of the problem and its significance.

Step 2: Determine the Causal Relationships


Cause and Effect relationships teaches us that everything that happens is
built upon an elemental set of causes consisting of conditions and action
causes coming together to cause an effect at a common place in time and
space.

Step 3: Identify Effective Solutions


Challenge the causes and determine the 'best' solution(s).

Step 4: Implement and Track Solutions


Implement and track solutions for effectiveness.

The causal relationships have been identified below:


Pump Failure Example Cont'd (Apollo) PAGE 5

Using the Apollo RCA Criteria check we identify the following effective
solutions:

1. Install overcurrent protection on the electric motor current supply


2. Implement a maintenance management system that enables maintenance
scheduling to resources and tracks maintenance completion/compliance.
3. Inspect all other pump that require impeller cleaning and perform
maintenance as a priority. This is known as a value adding solution.

Root Causes:

1. Excessive Current Draw


2. No overload protection
3. Maintenance not assigned to personnel

The 5-Why approach fails to address the excessive current draw and provide
an effective solution for this cause. Having overload protective devices
installed prevents reoccurrence, is within our control, meets the goals and
objectives and doesn't provide any other unacceptable problems.
Conclusions PAGE 6

The 5-Why tool causes us to ask why, why, why. As such we believe that A
caused B, B caused C, C caused D, and somewhere at the end of this causal
chain there is a magical single cause that started everything, i.e. the root
causes. The notion that causation is linear often results in ineffective problem
solving.

After diving deep into the heart of the problem using the powerful Apollo
Root Cause Analysis Methodology, we've uncovered a startling truth: even
seasoned experts can overlook crucial and effective solutions when relying
solely on the 5-Whys technique.

So here's what we asked ourselves: why settle for the 5-Whys method with all
its known and proven weaknesses? The answer we received is : "It's easy."

Don’t settle for a reactive approach that merely addresses the symptoms. Be
empowered to develop long-lasting solutions that eliminate the underlying
problems.

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