RCFA explained

RCFA (Root Cause Failure Analysis)

Root Cause Failure Analysis (RCFA) is a problem-solving method used to understand why a failure happened and how to stop it from happening again. Instead of just fixing the visible issue, RCFA digs deeper to find the underlying technical, human, or process-related cause.

For example, if a wire rope fails, an RCFA would go beyond simply replacing it. The investigation might reveal insufficient lubrication, contamination, or improper handling as the true cause. Once identified, corrective actions – such as using the right lubricator, improving inspection routines, or training staff – can be put in place to prevent future failures.

Practical RCFA Process

1. Define the problem
   Clearly describe what failed, when it occurred, and how it affected operations.
2. Collect data and evidence
   Gather maintenance logs, inspection reports, operator notes, and physical evidence from the failure.
3. Identify possible causes
   Brainstorm technical, human, and process-related factors that could have contributed.
4. Analyse and test hypotheses
   Use methods such as the “5 Whys” or fishbone diagram to trace the failure back to its true root cause.
5. Verify the root cause
   Confirm that the identified cause fully explains the failure and is supported by evidence.
6. Develop corrective actions
   Decide on solutions that address the root cause (e.g., better lubrication practices, equipment upgrades, or training improvements).
7. Implement and monitor
   Put corrective actions in place and track results to ensure the failure does not recur.

By applying RCFA, companies can reduce repeat breakdowns, extend equipment life, and improve both safety and reliability.