Training Agenda: Problem Solving with Root Cause Failure Analysis (RCFA)

Duration: 1 Day
Target Audience: Quality Engineers, Manufacturing Engineers, Team Leaders, and others involved in process improvement, problem solving, and corrective action.
Objective: To equip participants with the skills and knowledge to effectively solve problems using AIAG’s structured problem-solving methodology and Root Cause Failure Analysis (RCFA) techniques.

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Registration and Welcome

• Introduction to the course
• Course objectives and overview
• Participant introductions

Introduction to AIAG Problem Solving

• Importance of structured problem solving in manufacturing
• Overview of AIAG problem-solving methodologies
• Link between problem-solving, RCFA, and continuous improvement

The Problem-Solving Process (8D Overview)

• Overview of 8D problem-solving methodology
• Steps 1-3 in the 8D process:
  • D1: Form the Team
  • D2: Define the Problem
  • D3: Implement Containment Actions
• Practical exercise: Define a problem using real-world examples

Break

Root Cause Failure Analysis (RCFA) Techniques

• What is Root Cause Failure Analysis (RCFA)?
• Overview of common RCFA tools:
  • Fishbone Diagram (Ishikawa)
  • 5 Whys Analysis
  • Failure Mode and Effect Analysis (FMEA)
• How to use RCFA tools to identify root causes
• Practical exercise: Conducting a 5 Whys and Fishbone analysis on a sample problem

Lunch Break

Corrective Actions and Verification

• Steps 4-5 in the 8D process:
  • D4: Identify Root Cause and Verify
  • D5: Implement Permanent Corrective Actions (PCA)
• Best practices for designing and implementing corrective actions
• Practical exercise: Developing and evaluating corrective actions

Validating and Monitoring Solutions

• Steps 6-7 in the 8D process:
  • D6: Validate Corrective Actions
  • D7: Prevent Recurrence
• Tools for monitoring the effectiveness of corrective actions
• Practical exercise: Validating a corrective action plan using control charts and other tools

Break

Final 8D Step and Reporting

• Step 8 in the 8D process:
  • D8: Close the problem and celebrate success
• Documentation and communication of problem-solving results
• Preparing an 8D report: Best practices and real-world examples

Case Study Review

• Review of a real-world case study
• Group discussion: Lessons learned and application of RCFA in industry

Wrap-Up and Q&A

• Key takeaways
• Q&A session
• Feedback and evaluation