Module 1: Introduction to RCA and Mistake Proofing

• Objective: Understand the purpose, benefits, and applications of RCA and mistake-proofing.

• Topics:

  • What is Root Cause Analysis?

  • Why problems repeat: symptoms vs. root causes

  • Introduction to mistake-proofing (poka-yoke)

  • The role of RCA in continuous improvement and Lean/Six Sigma

Module 2: Problem Definition and Scoping

• Objective: Learn how to clearly define and scope problems.

• Tools & Techniques:

  • Problem statements (SMART problem framing)

  • SIPOC (Suppliers, Inputs, Process, Outputs, Customers)

  • Project scoping and boundaries

• Activity: Craft problem statements and scope examples.

Module 3: Data Collection and Evidence Gathering

• Objective: Build a fact-based foundation for RCA.

• Tools & Techniques:

  • Check sheets and data logging

  • Pareto analysis (80/20 rule)

  • Process mapping (flowcharts, value stream maps)

• Activity: Practice with a sample dataset to identify key failure patterns.

Module 4: The 5-Whys Method

• Objective: Apply the 5-Whys for root cause identification.

• Topics:

  • How to use the 5-Whys effectively

  • Pitfalls (jumping to conclusions, single-thread bias)

  • Linking with evidence

• Activity: Apply 5-Whys to a real-world case study.

Module 5: Cause-and-Effect (Fishbone/Ishikawa) Diagrams

• Objective: Use structured brainstorming for identifying potential causes.

• Topics:

  • Fishbone diagram structure (6 Ms, 4 Ps, or customized categories)

  • Brainstorming and team engagement

  • Integrating with 5-Whys

• Activity: Create fishbone diagrams for case examples.

Module 6: Advanced RCA Tools

• Objective: Introduce more sophisticated analysis methods.

• Tools:

  • Failure Mode and Effects Analysis (FMEA)

  • Fault Tree Analysis (FTA)

  • Barrier analysis & cause mapping

• Activity: Compare tools and select the best fit for different scenarios.

Module 7: Mistake Proofing (Poka-Yoke)

• Objective: Learn how to prevent recurrence of issues through design.

• Topics:

  • Principles of mistake-proofing

  • Types of poka-yoke (prevention vs. detection)

  • Examples in manufacturing, services, and healthcare

• Activity: Identify possible poka-yoke solutions in a simulated process.

Module 8: Sustaining Improvements and Reporting

• Objective: Ensure RCA findings lead to lasting improvement.

• Topics:

  • Developing corrective and preventive actions (CAPA)

  • Monitoring effectiveness of solutions

  • Reporting and communication strategies

  • Embedding RCA into organizational culture

• Activity: Write a mini RCA report with recommendations.