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Corrective Action Program Best Practice 9 – Perform Periodic Aggregate Analyses

StrategyDriven Corrective Action Program Article | Condition Report AnalysisCondition reports provide detailed information on individual performance deficiencies, operational events, and opportunities for improvement. While such information enables the resolution of specific problems, the aggregate analysis of all condition reports provides insight to the underlying systemic faults the correction of which would prevent recurrence of many of the organization’s issues.[wcm_restrict plans=”48883, 25542, 25653″]

Performing Aggregate Analyses

Periodic aggregate analyses seek to identify recurring event precursor performance deficiencies so that these issues can be mitigated prior to the occurrence of an impactful event. These analyses are commonly performed as follows:

  1. Aggregate condition report causal code counts (See StrategyDriven Corrective Action Program best practice article, Condition Report Causal Codes)
  2. Apply a weighting to the condition report causal code counts based on the significance level of the associated condition reports (See StrategyDriven Corrective Action Program article, Condition Report Prioritization)
  3. Determine the several analysis focus areas based on those area weighted aggregate causal code counts exceeding a predefined review threshold or having the greatest value
  4. Review the specific condition reports associated with the selected focus areas for commonality
  5. Identify those common causes the correction of which would have prevented or limited the impact of the majority of the documented issues
  6. Develop, implement, and track to completion those corrective actions needed to resolve these common causes. Recommendations should be captured within a separately developed condition report

Each analysis should, at a minimum, focus on significant weaknesses impacting the achievement of safety, reliability, regulatory requirements, industry standards and guidelines, and/or management expectations.

Frequency of Periodic Aggregate Analyses

In order for periodic aggregate analyses to be effective, they must be performed in a timely enough manner to identify and proactively eliminate underlying causal conditions before an event occurs. Consequently, organizations having mature corrective action programs typically perform a monthly, high-level aggregate analysis of condition reports written during the past month and an annual, detailed business performance assessment of condition reports written during the past year.[/wcm_restrict][wcm_nonmember plans=”48883, 25542, 25653″]


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About the Author

Nathan Ives, StrategyDriven Principal is a StrategyDriven Principal and Host of the StrategyDriven Podcast. For over twenty years, he has served as trusted advisor to executives and managers at dozens of Fortune 500 and smaller companies in the areas of management effectiveness, organizational development, and process improvement. To read Nathan’s complete biography, click here.

Corrective Action Program Best Practice 8 – Availability of Paper Forms

StrategyDriven Corrective Action Program ArticleAdverse conditions and opportunities for improvement present themselves in unexpected places, under unpredictable circumstances, to unsuspecting individuals. While an organization may use a corrective action program supporting application, the system may not be accessible or available to the individual observing the reportable event. To ensure reportable conditions are captured, paper-based condition report forms should be made available throughout the organization’s facilities.[wcm_restrict plans=”48873, 25542, 25653″]

Content of Paper Condition Report Forms

Paper-based condition report forms serve as a substitute for all software supported condition report types. Therefore, these forms commonly assume the basic report fields plus an additional checklist to allow for the proper report type identification. (See StrategyDriven Corrective Action Program best practice article, Employ Multiple Condition Report Types) Paper-based condition report fields include:

  • Condition Report Short Title
  • Condition Report Author*
  • Location, System, Equipment, Component, Procedure*
  • Date/Time of Condition Occurrence, Discovery, or Condition Report Creation*
  • Significance Level (See StrategyDriven Corrective Action Program article – Condition Report Prioritization)
  • Description of the Condition*
  • Immediate and Follow-up Corrective Actions
  • Causal Codes (See StrategyDriven Corrective Action Program best practice article – Condition Report Causal Codes)

* Required data

Distribution of Paper Condition Report Forms

Paper-based condition report forms should be readily available to all employees in order to effectively support problem reporting. (See StrategyDriven Corrective Action Program best practice article, Everyone Can Submit a Condition Report) To achieve this degree of availability, paper-based condition report forms are typically stored in operations control and ready rooms, maintenance shops, records libraries, departmental common areas, break rooms, and facility main entrances. Printable electronic versions of the paper form are usually maintained within the organization’s public document library.

Processing of Paper Condition Report Forms

Condition report authors submit their paper-based reports to their immediate supervisor or workgroup corrective action program coordinator for processing. These individuals process the condition report in accordance with the organization’s corrective action process protocols including entering the report into the electronic condition reporting system if applicable.[/wcm_restrict][wcm_nonmember plans=”48873, 25542, 25653″]


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About the Author

Nathan Ives, StrategyDriven Principal is a StrategyDriven Principal and Host of the StrategyDriven Podcast. For over twenty years, he has served as trusted advisor to executives and managers at dozens of Fortune 500 and smaller companies in the areas of management effectiveness, organizational development, and process improvement. To read Nathan’s complete biography, click here.

Corrective Action Program Best Practice 7 – Document Reasons for Condition Report Cancellation or Closure

StrategyDriven Corrective Action Program ArticleCondition reports requiring no processing past the Identification Phase are either cancelled or closed so to prevent the unnecessary expenditure of the organization’s resources. Reasons for the termination of condition report processing, however, should be well documented so to enable later evaluation of the appropriateness of this action. Furthermore, this documentation enables the initiator feedback necessary to ensure a high level of employee engagement with the corrective action program. (See StrategyDriven Corrective Action Program best practice article, Initiator Feedback)[wcm_restrict plans=”48866, 25542, 25653″]

Reasons for Cancelling or Closing Condition Reports

Several underlying differences exist between the reasons for condition report cancellation and closure. Condition reports are cancelled or rejected for one or more of the following reasons:

  • Reported condition does not meet the organization’s reporting criteria
  • Investigation determines the condition does not exist

Condition reports are close for one or more of the following reasons:

  • Condition requires no additional corrective actions and is coded for tracking and trending only
  • Duplicate open condition report or work order already exists

Documenting the Reason(s) for Condition Report Cancellation or Closure

In order to provide both an adequate historical record and initiator feedback, documented reasons for cancelling or closing a condition report should contain the following minimum information:

  • Date/Time of the cancellation or closure
  • Individual authorizing the cancellation or closure
  • Individual documenting the cancellation or closure
  • Statement of why the condition report was cancelled or closed including applicable elaborating data:
    • Applicable organizational standard(s) not met
    • Investigatory data supporting the assertion that the reported condition does not exist
    • Corrective actions taken to date and/or information supporting the assertion that no further actions are required
    • Causal codes (See StrategyDriven Corrective Action Program best practice article, Condition Report Causal Codes)
    • Open condition report or work order representing the same issue (See StrategyDriven Corrective Action Program best practice article, Check for Duplicate Condition Reports)

Differences in Treatment between Cancelled and Closed Condition Reports

Condition report treatment is dictated by the underlying reasons for their cancellation or closure. Cancelled or rejected condition reports are:

  • Eliminated to prevent the further valueless expenditure of processing resources
  • Excluded from historical condition report metrics

Closed condition reports are:

  • Archived because no further action is required
  • Included in historical counts for condition report metrics

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Nathan Ives, StrategyDriven Principal is a StrategyDriven Principal and Host of the StrategyDriven Podcast. For over twenty years, he has served as trusted advisor to executives and managers at dozens of Fortune 500 and smaller companies in the areas of management effectiveness, organizational development, and process improvement. To read Nathan’s complete biography, click here.

Corrective Action Program Best Practice 6 – Condition Report Causal Codes

StrategyDriven Corrective Action Program Article | Condition Report Causal CodesCondition reports provide detailed information on the organization’s performance deficiencies, operational events, and opportunities for improvement. That information, however, is typically captured in a voluminous long text format unconducive to the type of aggregate analysis providing insights to the underlying causes and precursor challenges required of proactive management action. Applying standardize, short text causal codes to condition reports helps overcome this analytical challenge.[wcm_restrict plans=”48861, 25542, 25653″]

Applying Condition Report Causal Codes

Condition report causal codes are commonly applied during two phases of the corrective action process. During the Initiation Phase when a condition report is first developed and reviewed, preliminary causal codes are applied based on the best available information. Problem causes at this point in the process, however, lack certainty because of the incomplete issue investigation and resolution actions. Therefore, causal codes are finalized during the Closure Phase once all activities are completed.

Initiation Phase causal codes are optionally applied by the condition report author; verified or applied by the reviewing supervisor; and verified by the condition report review committee. Closure Phase causal code finalization is performed by the manager or supervisor approving condition report closeout.

Common Causal Code Categories

While corrective action programs employ many difference types of condition report causal codes, four categories are foundational to any program:

How Discovered – Was the issue self-revealing, internally, or externally identified?

Purpose: Allows evaluation of whether the organization is proactive or reactive to issues and whether it is sufficiently self-critical. Some examples include:

  • Self-Revealing Event: Any ‘break-through’ failures in which equipment or programs made it obvious to personnel that an event had occurred. For example, if a valve was inadvertently left open and water spills on the floor when the system is turned on, the event is considered self-revealing. However, if the inadvertently left open valve was identified and corrected before the system was turned on such that water was not spilled on the floor, then event will is not considered to be self revealing.
  • Self-Identified: Any condition identified by the organization’s personnel, including contractors. For example, nearly all items identified during an equipment performance test are considered self-identified since the purpose of these tests is to identify discrepancies before they become problems.
  • Externally Identified: Any condition that is neither self-revealing nor self-identified is considered externally identified.

Impact Category – Did or could the issue directly result in a business unit or facility challenge or event?

Purpose: Identifies the severity of the issue, aids in the identification of issue significance, helps identify if additional action is warranted, and validates performance indicators. Some examples include:

Operational Impacts

  • Loss of 10 percent or more of production for more than 30 days
  • Unplanned facility outage
  • Planned facility outage extension of greater than 7 days

Cost Impacts

  • Greater than $750,000 loss
  • Greater than $150,000 and less than $750,000 loss
  • Greater than $50,000 and less than $150,000 loss

Equipment Failure

  • Unexpected equipment failure
  • Maintenance rework

Personnel Injury

  • Incident resulting in a fatality or permanent disability
  • Incident resulting in an OSHA Lost Work Day Case
  • Incident resulting in an OSHA recordable injury

Problem Category – Was the cause a process, people, or equipment problem?

Purpose: Allows statistical trending in major categories to determine if organizational performance is changing in any of these major areas.

Problem Type – What individual problem type (sub-tier of a Problem Category) occurred that resulted in the issue?

Purpose: Allows trending of expectations, behaviors, or equipment types causing issues.

Some examples of Problem Categories and sub-tier Problem Types include:

Worker Behaviors

Processes

  • Work Planning
  • Work Scheduling
  • Corrective Action

Management

Equipment

Additional Causal Code Categories

Mature corrective action programs leverage additional condition report causal code categories to expand the organization’s analysis capability. Applying these additional causal codes helps assessors gain deeper insight to underlying performance deficiencies; enabling proactive identification and resolution of issue precursors before an adverse outcome is realized. Common additional condition report causal code categories include:

Problem Causal Factor: What individual cause (sub-tier of a Problem Type) resulted in the issue?

Purpose: Allows trending of specific expectations, behaviors, or equipment failures causing issues.

Human Performance Precursors: What error precursors, such as weaknesses in recognition or implementation of human performance tools, directly resulted in the issue or did not prevent the issue from occurring?

Purpose: Allows trending of human performance issues, particularly the types of precursors that are occurring but may or may not be recognized.

Process: What specific process was involved or contributed to the issue?

Purpose: Provides data to determine recurring problems within a functional area or in a particular process.

Causing Organization: What organizational unit or workgroup was involved or contributed to the issue?

Purpose: Provides data to determine recurring problems within an organization or a particular group.

Key Words: Optional coding typically employed at the operational group or facility level.

Purpose: Provides flexible coding to uniquely code, track, and trend issues.[/wcm_restrict][wcm_nonmember plans=”48861, 25542, 25653″]


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About the Author

Nathan Ives, StrategyDriven Principal is a StrategyDriven Principal and Host of the StrategyDriven Podcast. For over twenty years, he has served as trusted advisor to executives and managers at dozens of Fortune 500 and smaller companies in the areas of management effectiveness, organizational development, and process improvement. To read Nathan’s complete biography, click here.

Corrective Action Program – Minimum Condition Report Data Requirements

StrategyDriven Corrective Action Program Article | Corrective Action Program - Minimum Condition Report Data RequirementsCondition reports capture adverse conditions or trends data so to enable an appropriate organizational response. Consequently, those documenting issues must provide enough information for responders to evaluate the condition within a timeframe consistent with its significance. Concurrently, too much data must not be required such that reporting problems is administratively burdensome or time consuming; creating a barrier to reporting. To ensure these objectives are met, minimum data reporting standards must be in place and reinforced.[wcm_restrict plans=”25541, 25542, 25653″]

Minimum Condition Report Data Requirements

Minimum condition report data requirements ensure the gather of the who, what, when, where, why, and how of an issue such that an initial follow-up investigation can be performed and corrective actions identified. Thus, four key data pieces are needed:

  • Who: Condition Report Author – Identifies the person reporting the issue so that follow-up inquiries can be made if necessary. In some circumstances, the person authoring the condition report may be doing so on behalf of the individual observing the issue. In these instances, the individual observing the condition should be identified within the Description of the Condition (see below) unless the observer wishes to remain anonymous. Note that anonymous condition reports are a critical, if not required, part of an Employee Concerns Program. (See StrategyDriven Corrective Action Program best practice, Anonymous Condition Reports)
  • Where: Location, System, Equipment, Component, Procedure – Identifies the item associated with the deficiency being reported so that follow-up inspections can be performed if necessary.
  • What, Why, and How: Description of the Condition – Describes, in detail, the adverse condition as well as known facts that may support follow-up investigations and facilitate corrective action identification. Immediate actions taken to address the condition should also be documented.
  • When: Date/Time of Condition Occurrence, Discovery, or Condition Report Creation – Identifies the time of adverse condition occurrence or discovery in order to aid follow-up research using other available data sources such as electronic monitoring sensors as well as to support reporting requirements as applicable.

Facilitating Minimum Condition Report Data Capture

Correctly configured, today’s corrective action program supporting applications automate and facilitate the gathering of minimum condition report data in the following manner:

  • Condition Report Author – Automatically captures the name and contact information for the individual creating the condition report based on his/her login information.
  • Location, System, Equipment, Component, Procedure – Provides an intuitive hierarchical dropdown list for physical assets (location, system, equipment, component) and procedures. Hierarchical lists are often organized by alpha-numeric designation followed by the item’s noun name. Items within the list should be readily recognizable and the alpha-numeric designation and noun names should match physical asset or procedure labels.
  • Description of the Condition – Provides help guidance that includes both an instructional guide and example as to the data and level of detail to be provided by the condition report author.
  • Date/Time of Condition Occurrence, Discovery, or Condition Report Creation – Automatically logs the date and time of condition report creation and provides the condition report author with additional fields to add the date and time of issue occurrence and/or discovery.

In the event that a condition reporting application is not use, paper or electronic forms should annotate the above data fields as required.

Reinforcing Minimum Condition Report Data Standards

Condition reports lacking the minimum required data place an additional resource strain on the organization as individuals performing follow-up investigations need to perform additional work to essentially ‘search’ for the problem. Therefore, reinforcing the minimum condition report data standards is critically important to building and organization habit of good reporting. Such reinforcement can be achieved through electronic and managerial practices.

For those organizations employing a corrective action program supporting application, the software can be configured to ensure the minimum condition reporting data is collected. In these instances, a condition report cannot be saved or submitted without all of the minimum data fields being completed. Furthermore, the system helps ensure data accuracy through the automatic completion of fields and reinforcement of data values using valid range (for example, allowing only a value of 0 – 24 hours in a day), type (for example allowing only numbers for dates and times), and format (for example allowing only MM/DD/YYYY for a date).

All submitted condition reports, whether within a program specific application or on paper, should be reviewed by the appropriate supervisor for completeness and accuracy. Those not meeting minimum data requirements or organizational standards should be returned to the condition report author for correction and the appropriate supervisory coaching provided.[/wcm_restrict][wcm_nonmember plans=”25541, 25542, 25653″]


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About the Author

Nathan Ives, StrategyDriven Principal is a StrategyDriven Principal and Host of the StrategyDriven Podcast. For over twenty years, he has served as trusted advisor to executives and managers at dozens of Fortune 500 and smaller companies in the areas of management effectiveness, organizational development, and process improvement. To read Nathan’s complete biography, click here.