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Root Cause Analysis (RCA) is a powerful methodology used to identify the underlying causes of recurring issues in manufacturing, operations, and quality systems. Unlike quick fixes that address only the symptoms, RCA digs deeper to uncover the source of the problem—whether it's physical, human, or systemic. This 2-day program offers a comprehensive, hands-on learning experience using real-world case studies, group discussions, and practical toolkits. Participants will explore essential tools such as the 5 Whys, Fishbone Diagram, Pareto Analysis, and FMEA, all while learning how to link RCA findings to effective corrective and preventive actions. Designed for aerospace manufacturers and technical teams, this course empowers participants to drive lasting improvements and foster a continuous improvement culture across the organization. This HRD Corp (HRDC) Claimable Course (Previously Known as SBL-Khas) Is Delivered by a Penang-Based Training Provider Registered with HRD Corp (Formerly Known as HRDF), Specializing in Corporate Skills Development and Workforce Upskilling Across Malaysia. 100% HRD Corp Claimable | Penang Training Provider | Corporate Training Malaysia
DAY 1
Module 1: Introduction to Root Cause Analysis
What is RCA and why it matters
Benefits of performing RCA
Types of causes: Physical, Human, Systemic
Common pitfalls in problem-solving
Activity: Quick group brainstorming on common workplace problems and their perceived vs. actual causes
Module 2: Problem Definition
Problem vs. Symptom
SMART problem statements
Stakeholder mapping for RCA
Activity: Draft SMART statements from vague problem descriptions
Lunch
Module 3: RCA Framework Overview
Reactive vs. Proactive RCA
RCA flow: Problem → Data → Root Cause → Solution
RCA’s role in Continuous Improvement (Kaizen, PDCA)
Activity: Interactive quiz and flowchart mapping
Module 4: RCA Tools & Techniques – Part 1
The 5 Whys Technique
Fishbone Diagram (Ishikawa)
Brainstorming & Affinity Diagrams
Activity:
- Case Study 1 – Customer Complaint on Product Delay → Teams use Fishbone Diagram and 5 Whys to identify root causes
DAY 2
Module 5: RCA Tools & Techniques – Part 2
Pareto Analysis
Failure Mode and Effects Analysis (FMEA)
Cause Mapping & Fault Tree Analysis
Activity:
Case Study 2 – Machine Downtime Incident → Teams conduct FMEA and Cause Mapping
Module 6: Data Collection & Analysis in RCA
Types of Data: Qualitative vs. Quantitative
Check Sheets, Histograms, Control Charts
Validating root causes with data
Activity: Data interpretation from sample defect logs
Lunch
Module 7: Corrective & Preventive Actions (CAPA)
Linking RCA outcomes to CAPA
Ensuring CAPA effectiveness
CAPA documentation best practices
Activity:
Case Study 3 – Quality Defects in Product Batches→ Teams develop and present CAPA plans
Module 8: Sustaining RCA in Organizations
Embedding RCA into daily operations
Leadership’s role in RCA success
RCA tracking systems and reporting
Building a problem-solving culture
Activity: Discussion on barriers and enablers to sustaining RCA
Module 9: Final Group Activity
Group RCA Challenge using a real-world case (client or trainer-provided)
Team Presentations & Peer Feedback
Activity: Full-cycle RCA project presentation with peer review
