Accidents don’t just happen—they have causes. Often, those causes go deeper than what appears on the surface. Root Cause Analysis (RCA) is a method businesses use to identify and fix the real reasons behind accidents. Instead of just treating the immediate issue, RCA uncovers why an accident happened and how to stop it from happening again.
This article explains how RCA works, why it matters, and how businesses can use it to improve workplace safety.
1. What is Root Cause Analysis (RCA)?
RCA is a structured way of getting to the bottom of workplace accidents. Instead of focusing only on what went wrong, it looks deeper to find why it went wrong. By identifying root causes, businesses can eliminate hazards at their source and prevent similar incidents in the future.
For example, imagine a worker slips on a wet floor and suffers an injury.
- The immediate cause is that the floor was wet.
- The root cause is that no one followed a procedure to clean the spill or put up a warning sign.
Addressing the root cause ensures the same accident won’t happen again.
2. Why is RCA Important?
Understanding why an accident occurred is essential for preventing future incidents. Without RCA, businesses often address only the symptoms, leaving the real problem unresolved.
Furthermore, RCA improves workplace safety by uncovering flaws in procedures, equipment, and training. Instead of just fixing what is visible, it forces organisations to dig deeper.
Here’s why RCA is essential:
- Prevents Repeat Accidents – Identifying the real cause stops future injuries.
- Strengthens Workplace Safety – It helps businesses fix weak policies and training gaps.
- Reduces Costs – Fewer accidents mean lower medical bills, legal fees, and compensation claims.
- Boosts Compliance – Businesses that investigate incidents properly are more likely to meet health and safety regulations.
- Protects Workers – A thorough approach to safety creates a healthier and more secure workplace.
Instead of reacting to accidents, companies that apply RCA focus on proactive prevention. This shift leads to a safer and more efficient work environment.
3. How to Find the Root Cause of an Accident
Step 1: Gather the Facts
Before drawing conclusions, collect all relevant information about the incident.
- Inspect the accident scene.
- Interview workers and witnesses.
- Review CCTV footage, maintenance records, and safety logs.
Step 2: Identify What Went Wrong
- Immediate cause – The direct reason for the accident (e.g., wet floor, faulty equipment, missing PPE).
- Underlying cause – Factors that contributed to the accident (e.g., lack of maintenance, poor training, or unclear procedures).
Step 3: Use RCA Tools to Find the Root Cause
To go beyond the obvious and uncover deeper issues, businesses use various RCA techniques:
✅ 5 Whys Method – Asking “Why?” multiple times helps uncover the root cause.
👉 Example:
- Why did the worker slip? – The floor was wet.
- Why was it wet? – A pipe was leaking.
- Why was the pipe leaking? – No one inspected it.
- Why wasn’t it inspected? – There was no maintenance schedule.
- Why was there no schedule? – The company never created one.
✅ Fishbone Diagram (Ishikawa Method) – A visual tool that categorises possible causes, such as equipment failures, human error, or environmental conditions.
✅ Change Analysis – Comparing conditions before and after an accident can highlight what went wrong.
Step 4: Fix the Root Cause
Once the real issue is identified, action must follow.
- Update safety policies to address gaps.
- Train workers to handle risks more effectively.
- Establish regular maintenance schedules.
- Improve supervision to enforce procedures.
Step 5: Monitor and Evaluate
It’s not enough to put solutions in place—businesses must ensure they work.
- Track whether the implemented changes are reducing risks.
- Gather feedback from employees on new procedures.
- Adjust policies if new hazards emerge.
4. Common RCA Mistakes
Even when organisations conduct RCA, mistakes can weaken its effectiveness.
❌ Blaming Workers Instead of Fixing Systems – Most accidents happen due to flawed procedures, equipment failures, or lack of training. The focus should be on fixing the system, not punishing individuals.
❌ Stopping at the First Cause – Many companies fail to ask enough questions. The first answer isn’t always the root cause. Keep digging deeper.
❌ Ignoring Near Misses – A near-miss is often a warning sign. Investigating these incidents can prevent future accidents.
❌ Failing to Follow Up – If businesses don’t check whether changes are working, the same risks will resurface.
For RCA to be effective, companies must commit to making lasting improvements.
5. Real-Life Example of RCA in Action
📌 Incident: A worker’s hand gets caught in a conveyor belt.
- Immediate cause: The worker’s hand was too close to the moving belt.
- Underlying causes: The emergency stop button was too far away. The worker’s clothing got caught in the machinery.
- Root causes: The machine design was unsafe. The company failed to provide proper training and risk assessments.
Solution:
- ✅ Move emergency stop buttons closer.
- ✅ Train workers on proper PPE use.
- ✅ Improve machine design to eliminate trapping points.
By addressing the root cause, the company prevents the same accident from happening again.
6. Final Thoughts
Root Cause Analysis makes workplaces safer by preventing accidents before they happen. By addressing the real causes of incidents, businesses can protect workers, reduce costs, and improve compliance.
Instead of waiting for the next accident, companies should use RCA to build a proactive safety culture. Every accident is an opportunity to improve—the key is asking “Why?” until you reach the real cause.
