Avoid the biggest failures in root cause analysis
In the world of reliability and maintenance, recurring equipment failures are more than just operational setbacks. They are costly disruptions that erode productivity, safety, and trust. Yet, many engineers and technicians still struggle with the fundamentals of effective root cause analysis (RCA). One of the most common misconceptions is the belief that there is always a single root cause.
In reality, complex failures often stem from a combination of causes and existing conditions. A narrow focus on identifying "the one root cause" can lead to incomplete investigations, missed insights, weak solutions, and ultimately, repeated failures.
The Real Definition of Root Cause
A root cause is not just a faulty component or a design flaw. It is an opportunity for improvement. It rarely exists in isolation. Effective RCA requires identifying both the transient initiating causes, and the contributing existing causes that allowed the failure to occur.
For example, a campfire needs a number of existing items to be in place before the transient spark ignites the fire: dry wood and oxygen, would both be existing causes that are needed to create the fire, if we remove either of these then the fire will not occur. Each of these existing causes presents opportunities for solutions to prevent reoccurrence of the fire, each of these causes is therefore a root cause, not just the transient spark.
Common Pitfalls in RCA and How to Avoid Them
1. Believing there is only one root cause
This mindset limits the scope of investigation and leads to tunnel vision. Complex failures often involve multiple interrelated causes. A robust RCA process encourages open-minded exploration and systems thinking.
2. Rushing the process
Time constraints often push teams to skip the preparation step and settle for quick fixes. While this may work for simple issues, it is inadequate for complex or recurring failures. Skipping steps or asking too few questions results in superficial solutions that do not prevent recurrence.
3. Lack of a structured process
Without a standardized RCA methodology, investigations vary in quality and depth. This inconsistency leads to unreliable outcomes and missed opportunities for systemic improvement.
4. Poor documentation and knowledge retention
When RCA findings are not properly documented or shared, valuable insights are lost. Teams end up repeating the same investigations, wasting time and resources.
5. Limited access to failure data
Without visibility into historical failure trends and maintenance records, engineers are forced to work in the dark. This makes it difficult to identify patterns or validate root causes.
Addressing the Challenges of Root Cause Analysis in Reliability and Maintenance
Reliability and Maintenance Engineers often encounter significant challenges when conducting root cause analysis. These include limited time, inconsistent investigation methods, fragmented documentation, and restricted access to historical data. These obstacles can lead to incomplete investigations and recurring failures that impact operational performance.
A key step toward overcoming these challenges is adopting a structured and repeatable approach to RCA. When teams are trained in a standard methodology, such as Cordant™ Root Cause Analysis, they gain the tools and confidence to conduct thorough investigations. This training helps establish a common language and process across the organization, which improves the consistency and quality of findings.
A structured methodology like the Cordant™ Root Cause Analysis process provide a clear path for identifying not only the immediate cause of a failure but also the contributing conditions. This comprehensive approach supports more effective problem-solving and fosters a culture of continuous improvement.
Applying a simple, reliable 3-step practice ensures consistency across investigations, whether big or small. Preparing well; gathering information and data, organizing people and a suitable venue, sets the investigation foundation. Analyzing the problem; by clearly defining the incident, working through a structured cause-tree build and performing repeated quality checks, all ensure the created chart is logical and justifiable. And finally resolving the incident; with carefully selected solutions for implementation and communicating the results and success across the organization.
Also of great importance is the ability to document and retain knowledge. When RCA findings are captured in a centralized and searchable system, such as Cordant™ Asset Defect Elimination, teams can avoid duplicating efforts and build on previous insights. This institutional memory becomes especially valuable in complex environments or when onboarding new team members.
Access to accurate and complete failure data is also essential. Engineers need visibility into maintenance records, performance metrics, and historical trends to identify patterns and validate root causes. Without this data, investigations are often based on assumptions rather than evidence.
Finally, tracking solutions and ensuring accountability are critical to closing the loop. It is not enough to identify a solution. Teams must implement it, monitor its effectiveness, and share the results across the organization to ensure that lessons learned lead to measurable improvements.
By investing in RCA training and adopting a consistent, data-informed approach to RCA, organizations can significantly improve their ability to prevent recurring failures and strengthen overall reliability.