Rothstein Associates Inc.

ROOT CAUSE ANALYSIS:
IMPROVING PERFORMANCE FOR BOTTOM-LINE RESULTS (Second Edition)
Kenneth Latino & Robert J Latino

* Introduces Enterprise Reliability Management System technology to identify the
most costly events in an organization
* Updates the PROACT software chapter to reflect the newest version
* Includes new client case histories illustrating the application and success of the
PROACT process
* Updates RCA implementation strategies
* Emphasizes and updates data collection strategies
* Expands the understanding of Physical, Human, and Latent Root Causes and
their
relationship to the mechanics of failures

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“Undesirable outcomes, chronic failure, incidents, and accidents… The cost of such events
to corporations is high, generally adding up to tens and hundreds of millions of dollars in
"accepted" losses. Why accept these losses? What if you could understand why these
errors occur and eliminate chronic events from occurring altogether?

“Root Cause Analysis: Improving Performance for Bottom-Line Results, Second Edition
shows how to identify, understand, and prevent chronic problems that hinder the attainment
of organizational goals using Root Cause Analysis (RCA). In addition, the PROACT
software,
voted "Product of the Year" by Plant Engineering Magazine, and the steps outlined in this
text teach you how to automate the RCA process. Used effectively, the information in Root
Cause Analysis will improve the reliability of your plant assets and save your company
precious time and money.”

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"Informative, well-illustrated and well-organized text…worthwhile reading for any plant
engineer seeking to understand why errors occur and how to eliminate them, and have a
direct positive impact on his company's bottom line."
- Jeanine Katzel, Plant Engineering Magazine

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"RCA should be used as a tool to help correct ongoing problems that are sucking dollars
from your organization…This book should be a standard part of any RCA practitioner's
'toolbox'."
- Bret Ridgway, Maintenance Resources

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"…if you read this book…you will be able to "Talk the Talk", and with the help of the
methodology explained, "Walk the Walk" down the path of improved equipment reliability
and
increased profits."
- John W. Vanauken, Inland Steel ISPAT

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"...Packed with a wide variety of subjects and detailed information for engineering
problem-solving...comprehensible and comprehensive...illuminating."
- Duy H. Hua, Kansas State University

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CONTENTS

Introduction to Root Cause Analysis
Failure Classification
Problems vs. Opportunities
Chronic vs. Sporadic Events
Creating the Environment to Succeed
The Role of the Champion
The Role of the Driver
The Role of the Analyst
Modified Failure Modes and Effects Analysis
The Manual Approach
Enterprise Reliability Management System (ERMS)
The Automated Approach
Preserving Event Data
The Error-Change Phenomenon
Data Collection Strategies for Chronic Events
Data Collection Strategies for Sporadic Events
Ordering the Analysis Team
The Ideal RCA Facilitator
The Ideal RCA Team Members
Their Roles
Analyzing the Data
Defining the TOP BOX
Developing Hypotheses
Validating Hypotheses
Identifying Physical, Human and Latent Root Causes
Communicating Recommendations & Findings
Developing, Prioritizing and Selling Recommendations
The Final Report
The Final Presentation
Tracking For Bottom-Line Results
Developing Tracking Metrics
Exploiting Successes
Creating the "Critical Mass"
Automating Root Cause Analysis
Introducing PROACT V2.0 Software
The Role of RCA in a CMMS Environment
Root Cause Analysis Case Histories
ISPAT Inland, Inc.
Eastman Chemical Company (Kingsport, TN)
LYONDELL-CITGO Refining
Eastman Chemical Company (Worldwide Customer Focus)
Alabama Power Company
Weyerhaeuser Company

Bibliography
Index

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ABOUT THE AUTHORS

“ROBERT J. LATINO is Vice President of Strategic Development for Reliability Center, Inc.
(RCI). RCI is a Reliability Engineering firm specializing in improving equipment, process,
and
human reliability since 1972. Mr. Latino received his bachelor's degree in business
administration and management from Virginia Commonwealth University. He has a special
interest in the theory of human error as applied to root cause analysis (RCA). Mr. Latino has
been a practitioner of RCA in the field with his clientele as well as an educator for 17 years.
Mr. Latino is an author of RCI's Root Cause Analysis Methods© course and coauthor of
Problem Solving Methods (PSM)© for Field Personnel. Mr. Latino has been published in
numerous trade magazines on the topic of RCA and is also a frequent speaker on the topic
at trade conferences.

“Kenneth C. Latino has a bachelor's of science degree in computerized information systems.
He began his career developing and maintaining maintenance software applications for the
continuous process industries. After working with clients to help them become more
proactive in their maintenance activities, he began instructing industrial plants on reliability
methods and technologies to help improve the reliability of their facilities.
Over the past few years, a majority of his time has been spent developing reliability
approaches with a heavy emphasis on root cause analysis (RCA). He has trained thousands
of engineers and technical representatives on how to implement a successful RCA strategy
at their respective facilities. He has coauthored two RCA training seminars for engineers
and
hourly people respectively.

“Mr. Latino is also the software designer of the RCA program entitled PROACT?. PROACT?
was a Gold Medal Award winner in Plant Engineering's 1998 and 2000 Product of the Year
competitions for its first two versions on the market. He is currently working with client
companies of Meridium, Inc. to integrate all of their reliability data and initiatives into an
automated enterprise reliability management system.”

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2002, 245 pages. Order #DR660.
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Brookfield, CT 06804-3104

1-888-ROTHSTEin

Telephone: 203.740.7444; 888.768.4783

Fax: 203.740.7401

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