COURSE OVERVIEW:

Effective problem-solving is the hallmark of a mature management system. This course provides a comprehensive framework for Root Cause Analysis (RCA) and Corrective and Preventive Action (CAPA), moving organizations away from superficial "Band-Aid" fixes toward permanent systemic solutions. Participants will learn how to investigate nonconformities with scientific rigor, ensuring that the true underlying causes are identified and mitigated to prevent recurrence.

The scope of this training involves the practical application of various RCA tools, such as the 5 Whys, Fishbone Diagrams, and Fault Tree Analysis. Attendees will explore the end-to-end CAPA process, from the initial containment of a problem to the final verification of effectiveness. The curriculum emphasizes the importance of data-driven decision-making and the role of cross-functional teams in uncovering complex causal factors that span multiple departments.

Coverage includes the documentation requirements for CAPA in accordance with ISO standards, the psychological aspects of human error, and the methodology for evaluating the impact of implemented changes. Participants will examine how to prioritize problems using Pareto analysis and how to ensure that corrective actions do not introduce new risks. By the end of this course, attendees will be able to lead high-impact investigations that drive continuous improvement and protect the organization’s reputation and bottom line.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the stages of the CAPA process according to ISO requirements.
• Differentiate between Correction, Corrective Action, and Preventive Action.
• Implement immediate containment actions to protect the customer.
• Apply the "5 Whys" technique to drill down to systemic root causes.
• Facilitate a Fishbone (Ishikawa) brainstorming session for complex issues.
• Utilize Pareto Analysis to prioritize problem-solving efforts.
• Conduct a Fault Tree Analysis for high-risk technical failures.
• Write clear and objective nonconformity statements.
• Design effective corrective action plans that address the root cause.
• Verify the effectiveness of implemented actions over time.
• Evaluate the relationship between human error and system design.
• Use RCA and CAPA data to drive management system improvements.

TARGET AUDIENCE:

Quality Engineers, HSE Officers, Maintenance Managers, Internal Auditors, and Production Supervisors responsible for problem-solving.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.