The Incidents That Warn You Before a Major Accident Happens

A major accident rarely happens without warning. Long before a serious injury, environmental release, or catastrophic failure occurs, there are usually multiple incidents pointing to underlying weaknesses in equipment, safeguards, work processes, or decision-making.

The problem is not a lack of incidents to learn from. The problem is how often those incidents are dismissed as “minor,” investigated superficially, or closed with corrective actions that focus on human error rather than system performance.

That’s why learning from precursor incidents is one of the most powerful ways to prevent major accidents, and how advanced root cause analysis makes that learning possible. A precursor incident is a minor incident that could have been a major accident if one or two more safeguards would have failed.

Our free white paper, Using TapRooT® Root Cause Analysis to Investigate Precursor Incidents and Major Accidents, was originally written to help others learn from early warning signs before serious events occur. This white paper has been used for years by safety, reliability, and operations professionals around the world. For 2026, it has been updated to reflect a few improvements we’ve made over the past couple of years while preserving the core principles that make it effective.

Moving beyond the “fire the employee” response.

One of the most compelling sections of the paper compares real-world corrective actions taken after a similar incident. In one case, the response was simple and familiar: discipline the operator. In the other, the TapRooT® Root Cause Analysis process was used to examine what actually happened, why it happened, and what needed to change to prevent recurrence.

The contrast is stark. While the “fire the operator” response feels decisive, it ignores critical system weaknesses. The TapRooT® investigation, by comparison, identifies multiple root causes and leads to corrective actions that strengthen equipment reliability, safeguards, work design, and management systems.

The updated 2026 white paper reinforces an important truth: effective investigations are not about assigning blame. They are about designing systems that make failure less likely.

A structured approach that supports better decisions.

Our white paper walks readers through how the TapRooT® Root Cause Analysis process is applied to precursor incidents and major accidents. It highlights the role of tools such as the SnapCharT®, Root Cause Tree®, and Corrective Action Helper® in guiding investigators to evidence-based conclusions and stronger corrective actions.

Rather than relying on experience, assumptions, or informal cause-and-effect thinking, the TapRooT® Process embeds human factors knowledge directly into the investigation. This helps investigators avoid common traps like confirmation bias and incomplete analysis, especially when human performance is involved.

Challenges facing your company in 2026 are not simple.

Work systems are more complex, staffing is tighter, and the tolerance for high-consequence failures continues to shrink. In this environment, ignoring early warning signs is a risk you can’t afford.

Our updated white paper reinforces why investigating precursor incidents is not extra work. It is preventative work. When done well, it reduces the likelihood of serious accidents, protects people and assets, and builds more resilient systems.

Download our updated 2026 white paper and see how investigating precursor incidents can prevent major accidents before they occur.