Resolving equipment failure causes by root cause analysis and theory of inventive problem solving

Failure causes of production systems need to be readily identified, for effective recovery solutions. Root cause analysis can be used for this, integrated by a method for identifying coherent and sustainable solutions. In this article, root cause analysis for failure cause identification is coupled with a method of problem solving to guide the search for effective solutions, called theory of inventive problem solving. The integration of these methodologies is implemented and demonstrated on a real case concerning the solution to the potential failure of the equipment used in the torque test performed on truck engines used in high-tonnage mining operation. The incorporation of a key performance indicator analysis allows evaluating realistically the results obtained and determining the success of the solution. © 2013 IMechE.