10/21/2020

Cause and Effect Analysis

Learning Objectives
• Understand the objective of a Cause and Effect analysis.
• List the major categories of causes.
• Using brainstorming, create a C&E diagram (fishbone diagram) to
aid communication and further investigation of the causes.

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Analyze
 Cause and Effect (C&E) analysis is the first step to
establish causal hypotheses and identify key
influencing factors for the CTQ parameters.
• Causal
 Ishikawa’s Fishbone Diagram – Professor Kaoru hypotheses
Ishikawa (1915 - 1989) • Key influencing
factors for
 Systematic identification of all sources that might Critical-to-
Quality
contribute to a process problem. parameters
• Prioritization of
 Team brainstorming improvement
projects

Major Categories of Causes

 Machine: equipment, computers, software required for the process

 Materials: raw materials, materials needed for the particular process step

 Measurements: data generated from process that are used to evaluate its
quality at that step

 Methods/Procedures: methods used to preform the process steps

 Manpower: operators, anyone involved with the process

 Environment: organizational structure, logistics, conditions, etc.

 Management/ Policies: higher-level decision rules

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Fishbone Curd: Expired, Ratio, Storing method

Banana: Ripeness
Sugar Syrup: Melting, Cleanness
Ice: Water used, Icing method, Storing, Packaging
Salt: Melting, Cleanness Ratio:
Powder Milk: Melting, Moisturizing, Grade :Full cream

Mixer Stick: Shape

Straw: Cleanness Density:
Potential to connect other substances
while resting
Hand masher:
-Replacement
- Maintenance
Fridge:

Lack of taste

Hand mixing: Hygine, time

Hand ice mashing: Hygine,
ice shape
Hand Glass washing:

Time: Temperature control:

Speed: Dust:
Performance:
Experience:
Hygiene:
©2012 from "A First Course in Quality Engineering: Integrating Statistical

Case Study – Bonding Failures

 Problems related to the failure of bonds after curing in a cable harness
assembly shop.

 The bonding takes place between rubber and plastic surfaces, with
bonding material applied in between. Pressure is applied, and the bonded
surfaces are cured in temperature-and humidity-controlled chamber.

 A bond is considered to be a failure when it does not meet the strength

requirements.

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Case Study – Bonding Failures

(From Ramachandran, B., and P.

Xiaolan, “A Quality Control Study of a
Bond Curing Process.” Unpublished
project report, IME 522, IMET
Department, Bradley University,
Peoria, IL, 1999.)

©2012 from "A First Course in Quality Engineering: Integrating Statistical

and Management Methods of Quality" by K.S. Krishnamoorthi. Reproduced
by permission of Taylor and Francis Group, LLC, a division of Informa plc.

Brainstorming
 A facilitator, who is not part of the team helps in these sessions acting as a
moderator.
 All ideas generated are recorded; no idea will be rejected at the initial
stages of idea generation.
 The facilitator will go around the table for ideas, so each member of the
team to make his/her contributions.
 At the end of the brainstorming session, the ideas are pruned, based on
consensus to avoid infeasible solutions.
 The resulting diagram will be presented to the team for voting to choose 4
or 5, of top candidate causes for further investigation.
©2012 from "A First Course in Quality Engineering: Integrating Statistical
and Management Methods of Quality" by K.S. Krishnamoorthi. Reproduced
by permission of Taylor and Francis Group, LLC, a division of Informa plc.