Team Root Cause Investigation

Achieving a Step Change

Improvement in Performance
By
Mike Mastic, Dow Chemical Company
and
Chris Eckert, Apollo Associated Services

Equipment Reliability - Track 3

1

Root Cause Investigation

Presentation Outline
Where Were We
The Case for Change
The Results
The Team Concept
The Work Process
Quality Assurance
Suggestions for Your Program
Q&A
2

Where Were We
As a Corporation
Pockets of expertise
Customized Apollo training
Corporate trigger list
Good electronic tools available globally
Customized RCI programs by business
All similar, yet all different
All have strengths and weaknesses
3

Where Were We
In Our Particular Business
For the facilitators, RCI = Burden
For those involved, RCI = Punishment
Ineffective facilitation
Hesitancy to deal with behavior issues
Ineffective corrective actions
Check-the-box validation
4

The Case for Change

2004 Before
% repeat
events

>10%

Event severity

High

# Quality
Incidents

>150

$$ Waste

$17MM

Culture

Redefining
Normal

The Results
2004 Before

2007 After

% repeat
events

>10%

<5%

Event severity

High

Much Lower

# Quality
Incidents

>150

35 in 2007
11 in 2008 YTD

$$ Waste

$17MM

$1.8MM

Culture

Redefining
Normal

Self Sustaining
Program

The Team Concept

Defining the Vision
Vision for the RCI Program
Disconnect RCI from punishment
Highly trained & capable facilitators
Common finished product regardless of
facilitator
Documented work process
Eliminate unplanned events
Address behavior issues appropriately
Monitor performance metrics
Change the culture
7

The Team Concept

Defining the Vision
Vision for Facilitators

Facilitation is a desired skill set

Facilitation is fun
Provide extensive training & mentoring
Facilitators must demonstrate proficiency
Remove the burden
Partnership Concept Facilitator & Event Owner
Avoid burn out
8

The Team Concept

Draw Your Own Box
Vision was in place but no action
I decided to act
Key Take-Away
Dont wait for someone else
Lead and others will follow

I framed the program, but was open to

input from others
9

The Team Concept

Securing Leadership Support
It was easy The business
leader was ready
Already had Quality & EH&S
Leaders support
Presented vision and scope of
effort
Asked for resources & support
10

The Team Concept

Assembling the Team
Determine size of team
Number of events
Capacity of the organization

Leaders identified potential candidates

Informed and approached candidates
Training available
Limit number of RCIs per month
There is an end in sight 2 year terms
11

The Team Concept

Team Leadership
Focal point for all RCI requests
Ensure trigger is met
Communicate pre-work expectations
Identify facilitator
Lead team meetings
Oversee training & mentoring process
12

The Team Concept

Training & Mentoring
Apollo RCA for Practitioner
RealityCharting software
Mentoring process
The stamp of approval
Succession planning

13

The Team Concept

Recognition
After proficiency is demonstrated
Monetary
Electronic / Public

14

The Work Process

Trigger Criteria
Event Owner contacts RCI Team Leader
Team Leaders guide
RCI Team facilitates significant events
Minor event exceptions

Reasons to increase thresholds

Success as a trigger
Dynamic analysis
15

The Work Process

Preparation & Pre-Investigation
Standardized documents
Evidence collection & analysis
Behavior issues
Team Leader identifies facilitator
Formal meeting scheduled (2 hour min)

16

The Work Process

Facilitation
We use Apollo RCA methodology &
RealityCharting software
Facilitators as independent third party
Outside area of expertise
Behavior issues
Facilitator control - Dont rush the process
17

The Work Process

Documenting
Facilitator sends reports & files to Event
Owner
RealityCharting file
Cause & effect chart export Adobe
Final report with solutions export to Word
Action item list export to Word

Event Owner documents event in

electronic reporting tool
18

The Work Process

Leveraging Learnings
During RCI Add to action item list
Add to electronic database
Monthly incident sharing with staff
Weekly safety meetings with operations
Leveraging the team concept

19

Quality Assurance
RCI Effectiveness
Six Sigma project results
Effectiveness criteria
Reporting

20

Quality Assurance
Event Validation
Last piece of program for our business
Validation Team
Production and Quality Leaders
6 Month waiting period
Action item review

Will lead to step change in performance

An RCI Program without effective validation

is just practice
21

Suggestions for
Your Program
Mikes Key Take-Aways
Dont wait
It wasnt hard
The team helped build the work process
and documentation
Program is still evolving
Personal recognition
Value of the team
22

Suggestions for
Your Program
Chris Key Take-Aways
You dont have to be a Sr. Manager to Lead!
Most people hesitant to lead, but happy to follow
Having Trouble Engaging Operations with your Reliability Efforts?
RCA yields fast, visible results. Operations will notice

Build the infrastructure first

Work Process
Incorporate R&R into personal goals
Training & mentoring pay off
Shortcutting will cost you far more

The Front Line: Engage Listen Act.

Measure Results & Share Success w/ Leaders
Savings & Effectiveness
23

Questions?

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