Root Cause Analysis and Failure Mode and Effects Analysis
Root Cause Analysis and Failure Mode and Effects Analysis
Gosbee L, et al. In Manasse H, et al., eds. Medication Safety: A Guide for Health Care
Facilities. Bethesda, MD: American Society of Health-System Pharmacists; 2005.
Human Factors in Device Design:
Medtronic SynchroMed Infusion Pumps
• Reports to the Food and Drug Administration (FDA) describe
accidental intrathecal injections of concentrated morphine during
attempts to refill Medtronic SynchroMed infusion pump, resulting in
fatal overdosages
• The pump is titanium and described as the size of a hockey puck
• The pump is surgically implanted under the skin of the abdomen or
flank and has a catheter that resides in the intrathecal space
• The small injection port on the front allows the drug supply to be
replenished via passage of a thin needle through the skin into the
port and thus into the drug reservoir
• A template to help locate this reservoir is included in the kit
• The problem arises because there is also a catheter access kit for
the device and its template is similar looking
• Identical-looking kits are the problem
Human Factors in Device Design:
SynchroMed Implantable Infusion Pump
Implantable infusion pump Refill kit template (above left) and catheter
access kit template (above right)
Human Factors Recommendations
• Use patient-controlled analgesia (PCA) pumps that read bar
codes to automatically set the concentration
– Strive to use a single concentration of analgesics
– Avoid stocking and using multiple concentrations of the same
drug that differ by a factor of 10 (e.g., 0.5 mg/mL and 5 mg/mL of
morphine)
• Carefully position syringe labels so important drug information
can be seen readily during pump setup and infusion
• Monitor patients frequently and have antidotes readily available
• Consider using oximetry and capnography for PCA patients
and those on continuous narcotic infusions
Human Factors Recommendations
• When new devices are purchased, use failure mode and effects
analysis (FMEA) to proactively identify design flaws and all points
at which user error might occur
• Establish a system of independent double checks when high-
alert medications are administered
• Avoid using pumps with a priming function that can deliver a
bolus during infusions
• If patients or family members will be using medication delivery
devices, provide them with clear spoken and written instructions;
alert them to potential user error with the devices; require return
demonstrations with sufficient practice to ensure competency
• Report drug-related device failure and user error to the USP-
ISMP Medication Errors Reporting Program and to FDA so timely
action can be taken to alert others to problems
Actions and Outcomes
• Obstacles can derail the RCA team’s work
– Lack of information about exactly why things happened
– Too broad or too narrow a focus
– Frequently recurring events
• Events happen again before corrective action implemented
• Ways to work through obstacles
– Collecting additional information through interviews with a broad
range of staff, patients, and families
– Simulating the event
– Focusing on the situation at hand
– Focusing on what can be done to prevent a similar situation rather
than becoming “hypnotized” by the event
– Researching what has been done in similar situations by using
research tools such as the Web and professional colleagues
Utility of RCA in the
Medication-Use Process
• Example Case: patient received a large dose of phenytoin
suspension, resulting in mild toxicity
– Immediate reaction, blame the nurse
– The RCA team, instead, found that system-level issues existed
– The resident who ordered the drug was confused about how to
express the dose in the order entry software
– The pharmacist finishing the electronic order was distracted
– The medication was supplied to the nurse in bulk bottles instead
of unit-dose packaging
• Fixing these system-level issues yields larger benefits
because more than one patient and more than one nurse
could be affected
Utility of RCA in the
Medication-Use Process
• Example Case: an RCA team looked at an event related to
the use of floor-stock IV solutions
– Blaming the nurse for selecting the wrong IV solution would
have been easy
– The RCA team, instead, looked into how the products were
replenished and the process for oversight of the items in
automated dispensing machines
– Systems-level improvements were implemented:
• Dispensing IV solutions with additives through the pharmacy
– Patients benefited from this action and nurses were freed from
some materials management activity
Tracing System-Level Vulnerabilities:
Case Report by the ISMP
• Partial patient identifier
– A handwritten order for carbamazepine 400 mg twice daily for an adult
patient was received by the pharmacist
– The patient profile was retrieved by typing the last name only
– The pharmacist inadvertently entered the medication into the profile of a
4-year-old child with the same last name
• Computer system weaknesses
– The pharmacist did not recognize that the dosage would be an overdose
for a small child
– The patient’s age was not in a prominent location on the order entry
screen
– The pharmacist could not match the prescribed medication to the patient’s
medical condition because the patient’s diagnoses and comorbid
conditions were not listed on the pharmacy profile
– Computer system did not require entry of a weight for pediatric patients
– No functional dose alerts in the system
Tracing System-Level Vulnerabilities:
Case Report by the ISMP (continued)
• Nonstandard medication administration record (MAR) checks
– The MAR was delivered to the patient care unit that night, but the nurse did
not notice the error
– MAR verification was not standardized in the hospital; different nurses doing
it different ways, if done at all
– No official policy requiring MAR verification, no written procedures, and
process not addressed during nursing orientation
• Adult dose and dosage form for a child
– The next morning, the nurse crushed the pills and gave the 4-year-old patient
the erroneous dose, failing to recognize it as too high for a child
– Nurse did not question why tablets were sent for a 4-year-old child
– Nurse did not inquire about a more suitable dosage form; the drug is
available in chewable tablets and as a liquid suspension
• Unverified patient history
– Nurse who administered the first dose assumed the child was receiving
carbamazepine because he had a history of seizures
Tracing System-Level Vulnerabilities:
Case Report by the ISMP (continued)
• Unverified patient history (continued)
– The child did not have history of seizures, but the nurse verbally passed that
erroneous information to the nurses on the next shift, and so on the
information was passed
– The child received three more doses in error, from three different nurses
• Language barrier
– The child’s parents were present when one dose was given
– The nurse tried to tell the parents the medication was used to control
seizures
– The parents and the child had a limited understanding of English and could
not intervene to correct the erroneous seizure history
• Poor physician access to MAR
– The physician did not detect the error during routine rounds
– The nursing MAR was not readily accessible for review
– No electronic or pharmacy computer-generated summary of prescribed
therapy on the chart
Tracing System-Level Vulnerabilities
Case Report by the ISMP (continued)
• Poor physician access to MAR (continued)
– The physician did not notice that the child was not receiving the
medication he prescribed
– The error was detected when the child became lethargic, developed
nausea and vomiting
– At this point the nurse suspected a problem with the dose and contacted
the physician
– The physician stated he had not prescribed carbamazepine for the patient
– The child’s carbamazepine level was 18 mcg/mL (normal therapeutic
range is 4–12 mcg/mL)
– This error delayed the child’s discharge, although he recovered without
further problems
• Errors are almost never caused by the failure of a single element in
the system
• Underlying system failures lead to errors that often can be identified
through RCA
No maximum
Ambiguous dose warnings Verbal
drug order Poor physician reporting Language
access to MAR barrier
Denning PJ. Human error and the search for blame. RIACS Technical Report TR-89.46; 1989.
Applying FMEA to
Medication Error Prevention
• FMEA asks what will happen if a health care provider:
– Mistakes one medication for another because of the packaging
– Administers the wrong drug or dose
– Gives a drug to the wrong patient
– Administers a drug by the wrong route or at the wrong rate
– Omits a dose
– Gives a drug at the wrong time
– Takes any action that may produce a medication error
• FMEA may reveal in some cases that:
– The patient can tolerate the error
– The error will be intercepted by the checks and balances built into the health
system’s quality improvement processes
– Specific steps must be put in place to address potential errors that are
intolerable
Designing Error Traps Can Prevent
Errors From Becoming Accidents
Knowledge Performance
Error Error
Safety System
(Error Trap)
Accident
Prevention
Learning About Potential Failure
Modes From Reported Errors
• Essential to develop a database of error modes by creating a
uniform and rational system of reporting errors and including
those that have not resulted in patient injury and near misses
– Locally (within a facility) or through larger databases
• ISMP is collecting this information in the United States, Canada,
and Spain
• A standard approach to reducing failures in mechanical and
electronic systems is the introduction of redundancy in critical
subsystems
• Multisensory channels could be used to prevent errors
– Example: changing the feel of packaging by making the syringe
rough or square
Application of FMEA
• FMEA utilizes before-the-fact evaluation rather than RCA
performed after an error
• RCA is essential, but analyzing processes and products before
problems occur is equally important to an organization’s
comprehensive medication error reduction strategy
• FMEA proactively identifies ways in which products or processes
can fail, why they might fail, how they can be made safer
• FMEA must employ an interdisciplinary team approach
• The Joint Commission requires a proactive risk assessment tool
and many organizations have chosen FMEA
Institute for Healthcare Improvement. Failure mode and effects analysis tools. Available at
www.ihi.org
An Application of FMEA
• Quantitative steps for FMEA approach
– Choose a high-risk process or product vulnerable to error
– Assemble an interdisciplinary team including those who prescribe,
dispense, administer, and monitor
– Describe and document the process
– Determine potential areas where errors may occur by looking at why
errors might happen considering areas such as the patient’s age,
tolerance to certain drugs, physician knowledge about the medication
– Decide if the potential errors are unacceptable by looking at
consequences for the patient and domino effect on the process
– Prioritize and take action to eliminate or reduce unacceptable errors
– Make sure the actions have been successful
• Table 21-1 illustrates the use of FMEA for analyzing PCA
• Table 21-2 illustrates the quantitative measure for the FMEA
VA Approach to FMEA
• Healthcare FMEA (HFMEA) was developed by the VA National
Center for Patient Safety (NCPS)
• HFMEA combines FMEA and the FDA’s hazard analysis and
critical control point (HACCP) concepts and decision tree with
definitions and tools from the VA’s RCA process
• NCPS found FMEA systems used successfully in industry
needed modification for use in evaluating health care processes
– Table 21-3 in textbook outlines the sources of concepts used in
HFMEA
– Table 21-4 in textbook compares HFMEA and RCA
– Specific terms used in HFMEA are defined on pages 577–8 in the
textbook
HFMEA Steps
1. Select a topic
2. Assemble the team
3. Graphically describe the process
4. Conduct a hazard analysis
5. Develop actions and outcome measures
HFMEA Steps: Selecting a Topic
• Topic should not be too broad or too narrow
• Patient safety officer (PSO) or medication safety officer along with
the quality or risk manager should select the topic
• The Joint Commission advises the use of available information
about sentinel events known to occur in health care institutions
that provide similar care and services
• Topic should have value to the institution and be justifiable to
auditors
• PSO should complete a rough flow diagram, using topic selected,
to outline the primary process steps as used in that hospital
• PSO should then select five or six steps that will be the narrow
focus of the HFMEA
• Sample flow diagram of HFMEA is shown in Figure 21-2 of
textbook
HFMEA Steps: Forming a Team
• The HFMEA team should be multidisciplinary
– Ensures multiple viewpoints are considered
• Including people who do not know the process ensures
critical review of the accepted standards and practices
and identification of potential vulnerabilities that others
might miss
– Reduces disciplinary bias
• Having at least two subject matter experts on the team
improves chances that the analysis has technical merit
• Designate a team leader and a team recorder
• PSO usually serves as an advisor and consultant
HFMEA Steps: Graphically
Describing the Process
• Develop the process flow diagram and verify it
• Number the process and subprocess steps on
the flow diagram
– A sample of subprocess steps is illustrated in
Figure 21-3 in the textbook
HFMEA Steps: Conducting a
Hazard Analysis
• Select a part of the process and conduct a hazard analysis,
listing and numbering all potential failure modes for each part
• Teams should employ different methods for identifying potential
failure modes
– NCPS triage cards for RCA
– Brainstorming
– Cause-and-effect diagramming
• Determine severity and probability and resulting hazard score
– Table 21-2 provides the hazard score matrix
– Table 21-5 presents the HFMEA definitions of severity
• Use a decision tree to determine course of action
– Figure 21-4 shows a hazard analysis decision tree
• Complete a separate worksheet for each failure mode
– Table 21-6 provides a sample failure mode worksheet
HFMEA Steps: Conducting a
Hazard Analysis
• The team completes the scoring for each failure mode before
moving on to failure mode causes
• Assess the failure mode if the hazard score is 8 or higher
• Team does not need to determine causes for low hazard failure
modes
– Low hazard failure modes are prioritized for action if the hazard is
a single-point weakness
• High hazard scores are de-emphasized if the failure mode has
an existing control measure or if it is detectable before the
event would occur
– Example of detectable hazard: a missing patient wristband
HFMEA Steps: Developing Action
and Outcome Measures
• Team develops a description of actions for each failure mode
selected for remediation
– Identifies outcome measures
– Designates a single person responsible for completing each
action
• Outcome measures for these actions could include setting a
date for checking to ensure that the module has been
activated and setting a date for testing the system
• A critical step is ensuring the system functions effectively and
new vulnerabilities have not been introduced elsewhere
• Leadership of the organization needs to be committed to each
recommended action
– If management does not concur, the team should revise the
action
The VA Experience
• VA used HFMEA with the topic: assessment of hospitals’
contingency processes for failure of the electronic bar code
medication administration (BCMA) system
– All VA facilities are required to have up-to-date and well-tested
contingency plans for medication administration
– NCPS staff prepared supporting documents and guidelines
– All VA facilities submitted HFMEA reports to NCPS in the fall of 2002
– An HFMEA project reviewed the best ideas from around the country
– Software to help facilities nationwide be in constant readiness
during BCMA downtimes was released
– Disasters, such as hurricanes and power failure, tested this but no
facility reported any major problems
• VA has found that staff now using HFMEA on more projects
Tips for Performing HFMEA
• Think of failure modes as “what could go wrong”
• Think of the failure mode cause as “why” the failure would occur
• Present failure modes as a problem statement that needs to be
corrected
• Ensure that the team diagrams the flow diagram steps that actually
occur, not the ideal process
• Once the team has diagrammed a process, post the flow charts in the
work area because staff not serving on the team may have ideas for
additional steps that have been forgotten or failure modes that no one
has suggested
• After the team develops the process diagram, have team members
visit the work area to observe staff performing the process and verify
that their assumptions are correct
• Follow the numbering and lettering format for the process and
subprocess diagrams
Tips for Performing HFMEA
• Chronological event flow diagrams used in RCAs are different
from process flow diagrams used in HFMEA
– RCA event diagrams show what actually happened on the day of
the event
– HFMEA process diagrams depict the usual activities
• For a failure mode or failure mode cause to be classified as
“detectable” on the HFMEA decision tree, it must be so visible
and obvious that it will be discovered before it interferes with
completion of the task or activity
• A single individual should be identified for follow-up on the
corrective actions identified on the HFMEA worksheet
• Use the most recent HFMEA worksheet; for the current version
visit to the VA Web site: www.patientsafety.gov
Tips for Performing HFMEA
• Conduct a hazard analysis on the failure mode before
identifying failure mode causes, so time is not spent
identifying causes when it is not necessary
• Pick projects of manageable size
• Failure modes can be tough to brainstorm
– Teams can use the literature, the facility’s own events, ISMP
medication safety reports, similar failures from other industries,
and the experience of team members
– If teams get stuck, they should take a break or use creativity-
building exercises to improve the flow of information
– Cause-and-effect diagrams can help by constantly raising the
question “Why?”
References
Denning PJ. Human error and the search for blame. Research
Institute for Advanced Computer Science. Technical Report TR-89.46;
1989.
Leape, LL, Woods DD, Hatlie MJ, et al. Promoting patient safety by
preventing medical error [editorial]. JAMA. 1998;280:1444–7.