Problem Solving & RCA training

Develop Strong Problem-Solving Capability with Root Cause Analysis (RCA)

Most organisations treat symptoms – firefighting sporadic breakdowns, quality issues and customer complaints – but never truly eliminate the chronic losses that silently drain productivity, quality and profitability.

Structured Problem Solving through Root Cause Analysis (RCA) provides a systematic, fact-based approach to diagnosing failures, uncovering contributing conditions and eliminating the sources of chronic losses. By strengthening analytical thinking, data usage and cross-functional collaboration, RCA empowers teams to shift from a firefighting mindset to a prevention-driven culture, significantly improving reliability, quality, cost performance and customer satisfaction.

Our Problem Solving & Root Cause Analysis Training equips your teams with a structured, data-driven methodology to identify, analyse and eliminate the true causes of problems, rather than repeatedly fixing the same issues on the surface.

Why is RCA critical for your organization?

Reduce rework and scrap

Eliminate Chronic quality issues

Improve process reliability

Enhance safety and compliance

Lower operational costs

Key Learning Objectives of RCA Training

Differentiate Chronic vs. Sporadic Losses

Understand the difference between sudden, visible problems and long-standing, hard-to-see losses – and when to use quick fixes versus deep problem-solving.

Apply a Structured Problem-Solving Methodology

Use PDCA / DMAIC and QC Story thinking: Define → Measure (Stratify) → Analyse → Improve → Check → Standardise → Horizontally Deploy.

Use Data Stratification & QC Tools Effectively

Move beyond opinions to fact-based decisions through stratification (by time, line, shift, machine, material, product, environment, workforce, etc.) and tools like histograms, Pareto charts and scatter plots.

Master Root Cause Analysis (RCA) Steps

Select priority issues using Pareto Analysis – Explore all possible causes with Cause & Effect Diagrams – Validate causes at the Gemba – Drill down with Why-Why Analysis – Define corrective & preventive actions with clear owners and timelines.

Design Robust, Preventive Solutions

Shift from temporary fixes to Poka-Yoke (mistake-proof) and preventive actions that protect all machines, lines and plants – not just the original problem area.

Who should attend RCA Training

Production & Maintenance Managers / Engineers

Quality & Process Improvement Teams

Lean / TPM / CI Coordinators

Supply Chain & Warehouse Teams facing recurring losses

Supervisors and Line Leaders who must solve problems on the shop floor daily

Equip Teams to Eliminate Recurring Issues with RCA Training Program

Chronic vs. Sporadic Losses – Where Should You Focus

How chronic losses hide inside “historical normal” performance.
Why flawed problem-solving approaches fail (no stratification, poor machine understanding, weak RCA discipline).
When to apply simple RCA vs. advanced analysis (PM Analysis) for complex, multi-cause problems.

Problem Solving Methodology – From Symptom to Solution

Introduction to QC Story / PDCA / DMAIC as a common problem-solving language.
Clear definition of problems using data and performance charts – turning vague issues into measurable “gaps”.
Crafting strong problem statements, themes and targets (what, where, when, who).

Observation, Gemba & Stratification

How to “go and see” with an open mind and avoid bias.
Identifying powerful stratification axes: time, line, shift, operator, material, supplier, product, environment, method, etc.
Practical exercises to show how incomplete data leads to wrong conclusions

Analysis using Systematic RCA approach

Pareto Analysis (80/20 Rule) Identify the vital few causes responsible for most of the losses.
Cause & Effect (Fishbone) Diagram: Structure potential causes under Man–Machine–Method–Material–Environment–Measurement. Move from scattered ideas to a clear cause map.
Why-Why Analysis: Drill down from symptoms to deeper systemic causes.

Validation at Gemba

Distinguish between “probable” and validated significant causes using data, standards and actual observation.
Converting root causes into practical corrective and preventive actions with clear owners, timelines and milestones, and conducting regular reviews.

Standardisation & Horizontal Deployment

How to lock in the gains through visual standards, SOPs and training.
Using before–after comparisons and control charts to verify improvement sustainability.
Horizontal deployment to similar parts, processes, machines and plants using structured rollout plans (e.g. Gantt charts).

Our RCA Training Experience

0 + 1000

RCA trainings conducted

0 + 3000

successful RCA projects

0 + 5000

participants trained

Why choose RIB as your training partner?

Experienced Trainers

Sharing of experience and case studies with practical application of RCA by Lean experts, worked across various industries and sectors.

Customised Training

The training program is tailored to align with organisation goals, by initial discussions with key stakeholders.

Practical Training

Practical learning through group activities, case studies, and simulation games, ensuring an engaging and hands-on experience at both classroom and shop floor of implementing RCA.

Train the Trainer Program

Train-the-Trainer program is led by a highly experienced trainer and Lean expert to enable internal capacity building and empower teams for ongoing success.

On-site and Off-site training

Flexible online and off-site RCA training programs designed to suit the needs of the organisation.

Result-oriented Certified Projects

Participants will get certification only after the submission of defined RCA projects and results delivered, ensuring target outcomes are achieved for each project.

Benefits of RCA Training

Eliminate Chronic Losses

Able to attack chronic losses systematically instead of firefighting.

Prioritise Critical Issues

Use facts and data to prioritise the right problems.

Standardisation

Apply a repeatable problem-solving framework across departments and sites.

Problem Solving Culture

Build a culture where people look beyond symptoms, find root causes and implement sustainable, standardised solutions.

A Glimpse into RCA Training

Advanced Lean Kaizen Certification Programs

Connect with our Experts!

With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!