10/24/2019 What Root Cause Analysis Tool Is Best for Operators?

What Root Cause Analysis Tool Is Best for

Operators?
Carl March, Life Cycle Engineering
Tags: root cause analysis, maintenance and reliability

Whenever you are asked to specify the best tool for an application, you must first
consider a few things before settling on an answer. You have to consider who is
going to use it, what this tool would be used for (its application), and what the
outcome is intended to accomplish. We know the answer to the first consideration
to be operators. With this in mind, let us step through the remaining areas of
concern to arrive at an answer.

1. What will the tool be used for?

Operators in the manufacturing and process industry environment play key roles in
the overall reliability of equipment. First, they should be the most familiar with how
their equipment should function under normal conditions. The difference between

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10/24/2019 What Root Cause Analysis Tool Is Best for Operators?

what that equipment should be doing and what it actually is able to do at a given
moment in time is the definition of a problem.

PROBLEM = SHOULD – ACTUAL

Early indications of the onset of a problem can frequently be noticed by operators
during the normal course of their duties if they are trained to be observant enough.
While the use of predictive technologies such as vibration analysis, ultrasonics and
infrared thermography will give a much earlier indication, operators are sometimes
called upon to be the last line of defense before failure occurs. So, one requirement
of the tool could be that it needs to be able to encourage and facilitate the use of
keen observation skills.

2. What end outcome is desired?

The quick answer to this question is that the chosen tool should be able to guide
the operator through the root cause analysis (RCA) process down to the root
cause(s) of the issue being examined. There are at least two other key outcomes
that would be beneficial for this tool to accomplish as well.

After the tool is used and the root cause(s) determined, there must be a system in
place which allows for the resolution of the issue. The tool should also lend to easy
application since the expectation would be that operators should be able to use it
fairly regularly as a part of their daily regimen.

The Tool for the Job

With all this in mind, I would highly recommend a variation of the 5 Whys problem-
solving methodology. The original 5 whys technique was developed by Sakichi
Toyoda and came to prominence in its use within the Toyota Production System.

The architect of the Toyota Production System, Taiichi Ohno, described the 5 whys
method as “the basis of Toyota’s scientific approach; ... by repeating ‘why’ five
times, the nature of the problem as well as its solution becomes clear.” Later, this
technique was also adopted into the Six Sigma methodology.

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10/24/2019 What Root Cause Analysis Tool Is Best for Operators?

The variation that I propose is called the Should-Actual 5 Whys (S-A-5Whys). In

this variation, before tracing a defect or problem to its root cause, initial focus is
spent determining when, in fact, a problem is occurring or about to occur.

How to Complete the Should-Actual 5 Whys

From keen observation, determine if a problem is occurring by comparing what
the asset or process should be doing under normal circumstances to how it is
currently performing.

Write down the specific problem, as indicated by the difference between the
“should” and “actual.”

Ask “why” the defect or problem is occurring, and write the answer down below
the problem.

Keep asking “why” until the team is certain that a root cause has been isolated.

Operators in a reliability-focused culture should have a questioning attitude and be

very observant. The inclusion of the S-A-5Whys tool in their skill set will benefit the
organization by the early identification and resolution of problems, leading to
increased asset reliability.

About the author:

Carl March has a wealth of experience in the areas of maintenance, reliability

engineering, systems modeling and design. Carl holds an undergraduate degree in
mechanical engineering and a graduate degree in automotive systems engineering.
As a reliability subject matter expert at Life Cycle Engineering, his passion and
focus is in the transfer of knowledge in RCM, TPM, root cause analysis and
Reliability Excellence to clients worldwide seeking to achieve manufacturing
distinction. Carl has attained a significant level of professional recognition as a
Certified Reliability Engineer (CRE) by the American Society for Quality and as a
Certified Maintenance and Reliability Professional (CMRP) by the Society of
Maintenance and Reliability Professionals. You can reach Carl at
cmarch@LCE.com.

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