The introduction of AI-powered Root Cause Analysis (RCA) in Fogwing CMMS promises to revolutionize how maintenance teams investigate recurring issues and improve operational efficiency.
What is Root Cause Analysis?
Root Cause Analysis (RCA) is a systematic approach to identifying the fundamental cause of a machine failure or recurring maintenance issue. Instead of addressing surface-level machine symptoms, RCA digs deeper to uncover the underlying factors that lead to machine failure.
RCA exercise involves data collection, analysis, and evaluation to pinpoint the "root cause" that, if resolved, will prevent the issue from recurring.
In machine maintenance, RCA typically follows these steps:
Problem Identification: Define the issue in detail, including symptoms, timelines, and affected components.
Data Gathering: Collect all relevant operational data, maintenance records, and observations.
Analysis: Use tools like the "5 Whys," fishbone diagrams, or fault tree analysis to systematically trace the issue to its root cause.
Implementation: Develop corrective actions addressing the root cause.
Validation: Monitor the machine's performance to ensure the solution effectively resolves the problem.
By applying RCA, maintenance teams can enhance machine reliability, reduce downtime, and minimize maintenance costs, ultimately improving overall operational efficiency.
Fogwing CMMS software provides an AI-powered Root Cause Analysis module to allow the maintenance team to prepare RCA reports against faults or failures reported. The following sections will guide you to prepare RCA using Fogwing CMMS.
Prerequisites for Root Cause Analysis
Fogwing CMMS allows the preparation of RCA reports against fault or failure work orders since not every issue requires RCA.
However, there are two prerequisites required to enable this feature in Fogwing CMMS.
Prerequisites 1 : Enabling Root Cause Analysis against Fault / Failure:
A fault code must be created with the RCA option enabled. Additionally, every fault work order should have a clear and accurate fault description, which will greatly influence the accuracy of the RCA results.
Prerequisites 2: Work Order Summary
Before initiating RCA, a summary of the fault work order should be prepared. This summary provides essential context for the analysis, particularly when leveraging AI to generate insights.
Key Features of RCA in Fogwing CMMS
The RCA feature in Fogwing CMMS is equipped with a variety of tools that streamline the process and make it user-friendly for maintenance teams.
RCA Dashboard
The RCA Dashboard serves as a centralized hub to track and manage fault work orders that require RCA. The dashboard consists of three main sections:Overview: This section helps you track the status of fault work orders, divided into:
To Do: Work orders that still require RCA initiation.
Completed: Work orders where RCA has already been completed.
Reports: Provides filtering options to search for RCA data based on fault codes, asset names, or corrective actions. It helps identify recurring issues and assess the effectiveness of corrective measures.
How to? Tab: A comprehensive guide to assist engineers and managers in applying the 5 Whys method for performing effective RCA.
Creating an RCA
Once a fault work order is completed, engineers or managers can initiate the RCA process through two methods:Manual Entry: Engineers can manually answer the 5 Whys questions to uncover the root cause.
AI-Generated RCA: By using AI-powered tools, the system can automatically generate an RCA based on the fault summary. The AI suggests responses to the 5 Whys and recommends corrective actions to prevent recurrence.
RCA Status Tracking
Each RCA will have one of the following statuses:Open: RCA has not started.
In Progress: RCA is currently being worked on.
Completed: RCA is finished and ready for review.
Maintenance managers can review and finalize RCA findings before taking corrective actions.
RCA Notifications
Fogwing CMMS helps teams stay on track with timely notifications:Initial Notification: Sent when the work order is closed, reminding engineers to begin RCA.
Reminder Emails: Sent 15 days before, one week before, and on the due date of RCA completion.
Escalation Email: If RCA is not completed a week after the due date, an escalation email is sent to the manager.
Who Should Use RCA?
Maintenance Engineers: They are responsible for initiating the RCA process after a fault work order is completed.
Supervisors and Managers: They review and finalize the RCA findings, propose corrective actions, and ensure the effectiveness of solutions implemented.
When and Why Should RCA Be Conducted?
RCA should be performed within 30 days after closing a fault work order for all relevant cases. Not all fault work orders require RCA; administrators can define which fault codes will trigger this analysis. Conducting RCA ensures that your team addresses the root cause of issues, preventing future breakdowns and optimizing asset performance.
The Impact of RCA on Operations
RCA is vital for pinpointing issues that are contributing to recurring asset failures. By identifying these root causes, your team can implement measures to prevent future breakdowns, enhance uptime, and improve overall asset reliability. This leads to greater operational efficiency, reduced downtime, and ultimately, cost savings.
Fogwing CMMS’s new AI-powered RCA feature is designed to streamline and accelerate this process, making it easier for your team to make data-driven decisions that improve maintenance strategies and boost asset performance.
Conclusion
With the addition of AI-powered Root Cause Analysis in Fogwing CMMS, you now have a powerful tool to address recurring issues at their source. By identifying and solving underlying problems, your team can reduce downtime, improve asset reliability, and create a more proactive maintenance culture.
For any questions or additional support on using the new RCA feature, feel free to reach out to us at [email protected]