Root Cause Analysis Syllabus

Root Cause Analysis
A quality process driven organization has a consistent standardized process in

developing and delivering their products and services. Having this system established,
understood and utilized creates a real differentiating factor in the marketplace which
delivers projects efficiently with comprehensive quality based documentation, tools and
techniques.
Root Cause Analysis is a class of problem solving methods aimed at identifying the root
causes of problems or events. This practice is predicated on the belief that problems are
best solved by attempting to correct or eliminate root causes, as opposed to merely
addressing the immediately obvious symptoms. By directing corrective measures at root
causes, it is hoped that the likelihood of problem recurrence will be minimized.
Participants will bring information on specific company projects to be worked on during

this training for real application of these concepts, tools and techniques.
 First, the basics of Root Cause Analysis are discussed to gain a common
understanding of the standard practices, tools and techniques that are utilized in
multiple industries.
 Next, participants will focus on gaining an understanding the standard practices,

tools and techniques that are applied to investigate the problem.
 Lastly, participants will apply these tools on specific company projects utilizing
Root Cause Analysis methodologies, tools and techniques.
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Course Syllabus
I IDENTIFYING INFORMATION
Course: Root Cause Analysis

Prerequisite: Understanding of the vehicle product development process
Understanding of basic product and manufacturing engineering
Time Frame: 40 total contact hours, 4 modules will be covered
Instructors: Bill Szuch Joe Tori
BS in ME and MBA BS in Journalism
30 years in engineering 30 years in engineering
Mobile: Bill Szuch (248) 762-2281 Joe Tori (248) 705-0807
E-mail: [email protected] [email protected]
II REFERENCE MATERIALS
1. Root Cause Analysis: Simplified Tools and Techniques, 2nd Edition by Bjorn
Andersen and Tom Fagerhaug
2. Apollo Root Cause Analysis: A New Way of Thinking by Dean Gano
3. The Basics of FMEA, 2nd Edition by Robin McDermott
4. Advanced Product Quality Planning and Control Plan, 2nd Edition by AIAG
5. Potential Failure Mode and Effects Analysis, 4th Edition by AIAG
6. Production Part Approval Process, 4th Edition by AIAG
7. Measurement Systems Analysis, 3rd Edition by AIAG
8. Statistical Process Control, 2nd Edition by AIAG
III COURSE GOALS AND OBJECTIVES
1. Understanding of the Root Cause Analysis philosophy and methodologies

2. Understanding of how to identify the root cause of the problem
3. Understanding of how to develop a solution
4. Understanding of how to validate the solution
5. Understanding of how to implement the solution
6. Application of a Root Cause Analysis system
IV METHODOLOGY
This course is a micro view of the Root Cause Analysis processes, tools and techniques.
We will be dealing with a detailed interpretation of meanings and applications as
applied to executing company projects. Each module will introduce new material that
will prepare the student for the projects to be completed.
Lectures
Each detailed subject will be presented in a lecture format outlining the theory and
standardized accepted methodology. A PDF file of the lecture material will be provided
for the student’s personal use as reference material. Lecture note outlines will be
distributed to the students for each lecture to help the student capture personal notes.
A short video showing the concept covered and a discussion regarding application.
Specific Industry Examples
Real life industry examples will be covered that detail out the application of the theory
to demonstrate how different companies apply these tools and techniques. This will
give the students a clear understanding of how and why these techniques are utilized at
different companies and industries in different manners.
In-Class Assignments
Using the theory and industry examples the student will conduct several projects that
outline each key principal on in-class projects. These projects will increase in complexity
as the students further develop their skills in applying these tools and techniques. The
students will present their work to the group for review and discussion.
Specific Company Application
As a summary of the training we will apply these tools and techniques on a specific
company project that is currently in development by the students. This will build a
standard methodology on how to appropriately apply the Root Cause Analysis processes
and principals at your company.
V COURSE OUTLINE & ASSIGNMENTS
Module 1
Introduction to Root Cause Analysis PowerPoint lecture
Industry Examples PowerPoint lecture
In-Class Assignment, finding the root Complete & present
Group Project PowerPoint lecture
Module 2
Introduction to Failure Mode & Effects Analysis PowerPoint lecture
Industry Examples PowerPoint lecture
In-Class Assignment, design FMEA Complete & present
In-Class Assignment, process FMEA Complete & present
Module 3
Developing the Solution PowerPoint lecture
In-Class Assignment, solution tools & techniques Complete & present
Module 4
Validation of the Root Cause PowerPoint lecture
In-Class Assignment, validation tools & techniques Complete & present
Implementation of the Solution PowerPoint lecture
In-Class Assignment, implementation tools & techniques Complete & present

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Root Cause Analysis

A quality process driven organization has a consistent standardized process in

Participants will bring information on specific company projects to be worked on during

 Next, participants will focus on gaining an understanding the standard practices,

Course: Root Cause Analysis

III COURSE GOALS AND OBJECTIVES

1. Understanding of the Root Cause Analysis philosophy and methodologies

Specific Industry Examples

Specific Company Application

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