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Training content
Overview
BRCGS Root Cause Analysis Training is designed to provide the knowledge and practical skills required to systematically identify the actual causes, rather than merely the visible symptoms, of non-conformities, errors, complaints and recurring problems, and to establish permanent corrective actions.
The language of the training is Turkish. The training is delivered online. The training provider is BRCGS.
About the Training
The training covers the concept of root cause analysis, the difference between a symptom and a root cause, problem definition, the evaluation of data and objective evidence, common root cause analysis methods, the difference between correction and corrective action, the development of effective action plans, the verification of actions, and the documentation of root cause analysis in accordance with BRCGS requirements.
Who Should Attend?
- Quality and product safety managers
- Technical managers and technical personnel
- Food safety team members
- Production and operations managers
- Internal auditors
- BRCGS auditors
- Consultants
- Personnel responsible for corrective action processes
- Personnel involved in complaint and non-conformity management
- Relevant personnel in production, storage, distribution and retail businesses
Objectives and Outcomes
The aim is to enable participants to distinguish between the visible symptoms of problems and their true root causes, select and apply appropriate root cause analysis methods, conduct cause analysis based on objective evidence, and develop effective corrective actions to prevent problems from recurring.
By the End of the Training
Participants will be able to:
- Explain the purpose and fundamental principles of root cause analysis.
- Identify the difference between a symptom, a direct cause and a root cause.
- Define problems clearly and accurately.
- Evaluate the objective evidence to be used in root cause analysis.
- Select the appropriate root cause analysis method.
- Apply analysis techniques such as 5 Whys and Fishbone Analysis.
- Explain the difference between correction and corrective action.
- Develop effective corrective action plans.
- Evaluate the effectiveness of actions.
- Document root cause analysis in accordance with BRCGS requirements.
Programme and Method
Overview of Root Cause Analysis
- Definition of root cause analysis
- Purpose of root cause analysis
- Problem-solving approach
- Difference between a symptom and a root cause
- Prevention of recurring problems
- Root cause analysis requirements in BRCGS standards
Problem Definition
- Clearly defining the problem
- Determining the scope of the nonconformity
- Assessing when and where the problem occurred
- Identifying the affected products, processes or systems
- Avoiding assumptions when defining the problem
Symptom, Cause and Root Cause
- The concept of a symptom
- Direct cause
- Contributing causes
- Systemic causes
- Root cause
- Distinguishing between the apparent problem and the actual cause
Gathering Information and Objective Evidence
- Reviewing documents and records
- Staff interviews
- On-site observations
- Process and equipment data
- Evaluating trends and historical records
- Cross-verifying evidence
5 Whys Analysis
- Purpose of the 5 Whys method
- Identifying the starting point of the problem
- Establishing the cause-and-effect relationship
- Using successive “why” questions
- Identifying the root cause
- Limitations of the method
- Practical examples
Fishbone / Ishikawa Analysis
- Purpose of the cause-and-effect diagram
- Human factors
- Machinery and equipment
- Method and process
- Material
- Measurement and monitoring
- Environment and working conditions
- Systematic evaluation of possible causes
Other Root Cause Analysis Methods
- Brainstorming
- Cause-and-effect analysis
- Fault tree approach
- Pareto analysis
- Process mapping
- Data and trend analyses
- Selecting the appropriate method according to the problem
Evaluation of Human Error
- Limitations of the “staff error” approach
- Training deficiencies
- Inadequate instructions
- Workload and working conditions
- Equipment and process design
- Supervision and management systems
- Identifying systemic causes
Correction and Corrective Action
- The concept of correction
- The concept of corrective action
- Short-term control of the problem
- Actions aimed at eliminating the root cause
- Prevention of recurrence
- Preventive approaches
Preparing the Corrective Action Plan
- Linking actions to the root cause
- Assigning responsibilities
- Setting completion timescales
- Planning the necessary resources
- Defining objective evidence
- Recording actions
Evaluating the Effectiveness of Corrective Actions
- Verifying implementation of the action
- Checking for recurring nonconformities
- Monitoring and data analysis
- Follow-up audits
- Assessing whether the action has achieved the desired result
- Establishing additional actions where necessary
Management of Recurring Nonconformities
- Identifying recurring problems
- Reviewing previous root cause analyses
- Evaluating inadequate actions
- Identifying systemic deficiencies
- Trend analysis
- Improving the management system
Root Cause Analysis for Complaints and Incidents
- Customer complaints
- Product nonconformities
- Process deviations
- Internal audit findings
- Certification audit nonconformities
- Product withdrawal and recall incidents
Root Cause Analysis for BRCGS Nonconformities
- Evaluating the audit finding
- Identifying the actual cause of the nonconformity
- Using objective evidence
- Linking corrective actions to the root cause
- Actions aimed at preventing recurrence
- Correctly documenting the root cause and actions
Documentation of Root Cause Analysis
- Problem definition
- Evidence investigated
- Analysis method used
- Identified root cause
- Correction
- Corrective action
- Responsibility and completion date
- Effectiveness verification
Common Mistakes
- Accepting the symptom as the root cause
- Concluding the analysis with “staff error”
- Using insufficient data
- Drawing conclusions based on assumptions
- Confusing correction with corrective action
- Defining actions unrelated to the root cause
- Failing to verify effectiveness
Case Studies
- Evaluating example nonconformities
- Application of 5 Whys analysis
- Application of Fishbone analysis
- Root cause analysis arising from a complaint
- Audit nonconformity scenarios
- Preparing a corrective action plan
- Evaluating action effectiveness
Training Method
The training is delivered through subject presentations, evaluation of BRCGS requirements, case studies, 5 Whys and Fishbone exercises, problem-solving exercises, analyses of example nonconformities and the preparation of corrective action plans.
Attendance and Certificate
Certificate Policy
A certificate of attendance is issued to all participants whose attendance has been confirmed. To receive a certificate of achievement, participants must obtain a passing grade in the examination at the end of the training; participants who use all their examination attempts but do not pass will be issued a certificate of attendance.
FAQ and Resources
Who is the BRCGS Root Cause Analysis Training suitable for?
It is intended for personnel involved in quality and product safety management, non-conformity, complaint and corrective action processes within manufacturing, storage and distribution, and retail businesses, as well as auditors and consultants.
What is the main objective of the training?
To enable participants to go beyond the visible symptoms of problems, systematically identify the true root causes and develop effective corrective actions to prevent problems from recurring.
Why is root cause analysis important?
Root cause analysis ensures not only that the existing non-conformity is corrected, but also that the underlying causes of the problem are eliminated and the recurrence of the same or similar non-conformities is prevented.
Is the training practical?
Yes. The training includes case studies, example non-conformities, the 5 Whys, Fishbone Analysis and other problem-solving methods, as well as exercises in developing corrective actions.
Is there an examination at the end of the training?
Yes. An assessment examination is administered at the end of the training.
References
- BRCGS Root Cause Analysis Course Materials
- BRCGS Global Standards
- BRCGS Product Safety Management Guidance
- BRCGS Corrective and Preventive Action Guidance
- Relevant BRCGS guidance and manuals