COURSE INTRODUCTION
This program is designed to develop strong problem-solving capability using proven methodologies such as Toyota 8 Steps, 8D Discipline, and 5 WHY Analysis, enhanced with Data-Driven and AI-Augmented techniques.
It focuses on practical application, real case analysis, and prevention of recurrence through strong corrective actions and Poka Yoke design.
COURSE OBJECTIVES
Participants will be able to:
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Understand and apply RCA structured methodology
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Avoid common RCA failures and mindset issues
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Develop strong problem definitions
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Perform effective 5 WHY and root cause validation
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Use data for analysis and decision making
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Apply AI tools to enhance RCA quality
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Develop effective and permanent corrective actions
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Implement Zero Defect thinking using Poka Yoke
COURSE OUTCOMES
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Improved RCA capability
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Reduction in recurrence issues
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Stronger problem-solving mindset
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Better data-driven decision making
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Introduction to AI-supported RCA
METHODOLOGY
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Interactive lecture
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Real case study analysis
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Group workshop
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AI-assisted exercises
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Discussion and reflection
WHO SHOULD ATTEND
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Engineers
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Supervisors
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Quality Personnel
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Manufacturing Personnel
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Technical Managers
COURSE CONTENT
PART 1: RCA FOUNDATION
PART 2: WHY RCA FAILS
PART 3: DATA-DRIVEN RCA
PART 4: AI-AUGMENTED RCA
PART 4.8: POKA YOKE & ZERO DEFECT
PART 4.9: CONTROL HIERARCHY
PART 5: PRACTICAL WORKSHOP
