Root Cause Analysis (RCA)
Stop the failure, not just the symptom.
Structured, evidence-led investigation of major failures — from physical mechanism to latent management cause.
Request AssessmentWhat we typically find
- Investigations that end at 'bearing failure' without explaining why the bearing failed.
- Corrective actions that are never verified or that address the wrong cause.
- The same incident recurring after the equipment is repaired and returned to service.
What the engagement covers
- Incident facilitation and evidence preservation
- Physical, human and latent cause analysis
- Component examination, metallurgical and lubrication evidence review
- Corrective and preventive action (CAPA) definition
- Verification plan and effectiveness review
How we deliver it
Preserve
Secure failed components, process data, alarms and witness statements before evidence degrades.
Reconstruct
Build a timeline of operating conditions leading to the event.
Analyse
Apply logic-tree analysis to separate physical mechanism, human factors and latent system causes.
Verify
Test each hypothesis against physical evidence; discard causes that cannot be supported.
Close out
Define CAPA with owners and dates, then review effectiveness after a defined operating period.
Deliverables
- RCA report with evidence log and logic tree
- Confirmed failure mechanism and contributing factors
- CAPA register with owners, dates and cost estimates
- Verification and effectiveness review plan
Outcomes
- Elimination of recurring high-cost failures
- Documented, auditable investigation record
- Learning transferred to similar assets across the site
Every recommendation is traceable to a recognised standard.
Discuss root cause analysis (rca)
A 30-minute call is usually enough to tell whether this is the right starting point for your plant.
Related services
Criticality analysis, FMEA, RCM and reliability modelling that target the failures actually costing you production.
PM optimization, task rationalisation and spare parts strategy that cut wasted maintenance hours without adding risk.
Vibration, thermography, ultrasonic, lubrication and thickness programmes designed around real failure mechanisms.