Conducting a Root Cause Analysis Course (2 days)

Categories: Root Cause Analysis
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About Course

Every food business has a non-conformance register, and most registers show the same problems coming back: the same CCP deviation, the same complaint category, the same swab site. Each one has a closed corrective action next to it. The action was completed. It just did not work, because it treated the symptom instead of the cause.

This course teaches you to run a root cause analysis that stands up to an auditor and, more importantly, stops the problem coming back. You will learn a structured, evidence-based method: define and contain the problem, preserve evidence and build a timeline, understand the people in the system, use the right cause-finding tools, verify the root cause, and design corrective actions strong enough to work.

How you learn

  • 12 modules of short video lessons, each with full written notes you can study without playing the video.
  • One running case study across the whole course: a recurring foreign-body complaint at a ready-to-eat meat plant. You investigate it step by step, from problem statement to final report.
  • Interactive activities in every module, with instant feedback.
  • Practical exercises with model answers and a self-assessment checklist, plus an extension to apply each tool on your own site.
  • Knowledge checks after each module and a final assessment (50 questions, 70% to pass, three attempts).
  • Certificate of Completion from ASC, a FoodBev SETA accredited training provider.

Standards and law covered

FSSC 22000 and ISO 22000 (corrections, corrective actions and handling potentially unsafe product), BRCGS Food Safety Issue 9, and the South African framework including R638 and R607 under the Foodstuffs, Cosmetics and Disinfectants Act.

Study at your own pace

The course is online and self-paced, with lifetime access. Allow about 16 hours in total: roughly two working days, or a module a week alongside your job.

What Will You Learn?

  • Tell symptoms, direct causes, contributing factors and root causes apart
  • Separate correction, corrective action and preventive action in your records
  • Meet FSSC 22000, ISO 22000, BRCGS Issue 9, R638 and R607 requirements for non-conformity and RCA
  • Decide, with a risk-based trigger, when a full RCA is needed
  • Write a problem statement and Is/Is Not specification that narrows the search
  • Contain the problem and decide product disposition
  • Preserve evidence, use check sheets, run charts and Pareto analysis, and build a timeline
  • Look past "human error" using the Swiss cheese model, error types and just culture
  • Run an investigative interview that produces facts, not defensiveness
  • Build a fishbone diagram and a multi-leg 5 Whys why-tree with evidence at each step
  • Use cause-and-effect charts, fault trees, barrier analysis, bow-ties and change analysis
  • Verify a root cause and write a statement an auditor will accept
  • Design strong corrective actions, escape the retraining trap, and verify effectiveness
  • Use 8D, A3, FMEA and PDCA to organise and report an investigation
  • Write a one-page RCA report and brief management in three minutes

Course Content

MODULE 1: FOUNDATIONS – WHY RCA FAILS, AND WHAT GOOD LOOKS LIKE

  • Lesson 1: Module 1 Learning Outcomes and Introduction
  • Lesson 2: A Problem That Keeps Coming Back
    03:32
  • Lesson 3: What Is Root Cause Analysis
    04:40
  • Lesson 4: Correction, Corrective Action and Preventive Action
    07:38
  • Activity: Classify the Cause, Classify the Action
  • Lesson 5: Why RCAs Fail in Food Plants
    03:16
  • Lesson 6: The Red Bead Experiment
    02:48
  • Lesson 7: Core Principles of Good RCA
    04:08
  • Lesson 8: The Types of Root Cause
    07:53
  • Lesson 9: A Brief History
    06:44
  • Practical: Reclassify and Critique Highveld’s Closed Complaint Records
  • Module 1 knowledge check

MODULE 2: WHAT THE STANDARDS AND THE LAW REQUIRE

MODULE 3: DEFINING THE PROBLEM AND CONTAINING IT

MODULE 4: EVIDENCE, DATA AND THE TIMELINE

MODULE 5: PEOPLE IN THE SYSTEM: HUMAN FACTORS AND INTERVIEWING

MODULE 6: BRAINSTORMING AND THE FISHBONE DIAGRAM

MODULE 7: THE 5 WHYS AND THE WHY-TREE

MODULE 8: CAUSE CHARTS, FAULT TREES, BARRIERS AND CHANGE ANALYSIS

MODULE 9: SELECTING AND VERIFYING THE ROOT CAUSE

MODULE 10: CORRECTIVE AND PREVENTIVE ACTION THAT ACTUALLY WORKS

MODULE 11: 8D, A3, FMEA AND PDCA

MODULE 12: REPORTING, TEAMWORK AND BUILDING AN RCA CULTURE

Course Assessment and Feedback

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