When Fixes Fail: Why Some Problems Keep Coming Back

It starts with a familiar scene:

A machine fails. A production target is missed. Someone is sent to patch it. Everyone gets back to work — until it happens again.

And again.

Each time, there’s a temporary fix. But the problem never truly goes away. It just lies in wait, ready to pop up when you least expect it.

Sound familiar? This is what happens when we treat symptoms instead of solving root causes.

The Real Cost of Patch Jobs

At first, a quick fix seems efficient. It gets operations back online fast. No meetings, no deep dives, no disruption.

But what’s the long-term cost?

• Recurring downtime

• Wasted resources

• Safety risks

• Staff frustration

• And most dangerously — a false sense of control

In high-stakes environments like mining, power generation, and manufacturing, these ripple effects can be enormous.

The truth is: patching is a habit. And like most habits, it feels easier than change. But solving recurring problems requires a shift — in mindset, in method, and in team culture.

Why Problems Keep Coming Back

It’s not because people are lazy or careless. It’s usually because they’re working without structure.

• Investigations are rushed

• Evidence is missed

• Assumptions take over

• Human factors are ignored

Solutions are applied without testing their relevance to the actual cause. In these conditions, even the best people can’t succeed consistently.

That’s why structured Root Cause Analysis (RCA) makes all the difference.

A Better Way: Sologic’s 5-Step RCA

At Sologic, we teach a methodical, collaborative way to investigate and solve complex problems. Our 5-step RCA process guides teams from chaos to clarity:

1. Gather Evidence – Start with facts, not assumptions

2. Define the Problem – Be precise and align on scope

3. Analyse Cause and Effect – Use visual maps to make logic visible

4. Generate Solutions – Target the right causes with the right actions

5. Report and Share – Build trust and accountability across the team

This isn’t about bureaucracy or blame. It’s about building a culture that solves, learns, and improves together.

When Structure Meets Reality

Here’s a real-world example:

A site was battling repeated slurry pump seal failures. Despite swapping out seals and tightening maintenance routines, the leakage kept coming back — costing time, cleanup, and lost production.

On the surface, it looked like a simple mechanical wear issue. But when the team applied a structured Sologic RCA, the real picture emerged:

• The gland seal flush water line was partially blocked

• This blockage led to insufficient seal lubrication and cooling

• There was no flow indicator on the line to flag reduced flow

• And maintenance crews weren’t trained to inspect the line during routine checks

These weren’t isolated issues — they were connected causes. Once the team built a cause-and-effect chart, the gaps in system design and procedure became visible — and fixable.

With structure, the right solutions stood out:

• Clear inspection criteria

• A flush line flow monitor

• Training on what to look for and why it matters

This is the difference between patching a leak… and solving the problem for good.

Since addressing the actual causes, the problem hasn’t come back.

What Can Sologic Do for You?

If you’re firefighting recurring problems, chasing targets, or trying to upskill your team, we can help.

We provide:

• Practical RCA training (for frontline teams to executives)

• Expert-led facilitation (for your toughest investigations)

• Causelink software (to keep your RCA structured and scalable)

Our goal? To help you stop patching — and start solving.

Want to explore how structured RCA could work in your team? Let’s talk!

Visit https://sologic.com/en-au for more details.