Professional Documents
Culture Documents
Root Cause Analysis
Root Cause Analysis
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Course Objectives
What is Root Cause?
Benefits
The Problem Solving Process
ROOT CAUSE =
The causal or contributing factors that, if corrected, would prevent
recurrence of the identified problem
The factor that sets in motion the cause and effect chain that creates a
problem
identifying a problem
containing and analyzing the problem
defining the root cause
defining and implementing the actions required to
eliminate the root cause
validating that the corrective action prevented
recurrence of problem
Not knowing the root cause can lead to costly band aids.
USUAL APPROACH
Firefighting! Problem
Problem
Immediate Containment reoccurs
Identified
Action Implemented elsewhere!
Find
someone to
blame!
PREFERRED APPROACH
Immediate Defined Solutions are
Solutions
Problem Containment Root Cause applied across
validated
Identified Action Analysis company and
with data
Implemented Process never return!
CUSTOMER
“Customer” can be
Internal or External
CUSTOMER
CUSTOMER
CUSTOMER
Immediate action
The action taken to quickly fix the impact of the problem so the “customer” is
not further impacted
The action taken to eliminate the error on the affected process or product
The action taken to Prevent the error from recurring on any process or product
Changed product design to make parts easier to assemble Changed design guidelines to not allow for use of part in full
manually scale production
All documents that are critical to project are identified with red
Specific customer document critical to project is identified with folders
red folder
1
Identify
8 Problem 2
Validate Identify
Team
7 3
Problem
Follow Up
Plan Solving Immediate
Action
Process
Complete Root
Plan Cause
Action
6 Plan 4
5
© 2004 Superfactory™. All Rights Reserved. 20
Step #1
5W2H
Who? Individuals/customers associated with problem
What? The problem statement or definition
When? Date and time problem was identified
Where? Location of complaints (area, facilities, customers)
Identify Team
When a problem cannot be solved quickly by an individual, use a
team!
Immediate Action
Rework
Root Cause
Tools
brainstorming 5 Why
flowcharting failure mode, effect & criticality
cause & effect diagrams analysis
pareto charts fault tree analysis
barrier analysis
change analysis
5 Why’s
Materials Methods
Environment Effect
Equipment People
NOTE: Causes are not limited to the 5 listed categories, but serve as a starting point
Allow team members to specify where ideas fit into the diagram
Clarify the meaning of each idea using the group to refine the ideas. For
example:
Materials Methods
Traffic Delays
Shipping
Environment
Wrong Equipment
Problems
Weather Driver
Dispatcher Attitude
Breakdown Dirty Equipment Wrong Directions
Equipment People
Define exactly…
What actions will be taken to eliminate the problem?
Who is responsible?
Verification
Assures that at a point in time, the action taken will actually do what is
intended without causing another problem
Validation
Provides measurable evidence over time that the action taken worked
properly, and problem has not recurred
Make certain all actions that are defined are completed as planned
If the plan is compromised, most likely the solution will not be as effective
Follow Up Plan
What actions will be completed in the future to ensure that the root cause
has been eliminated by this corrective action?
Who will look at what data?
How long after the action plan will this be done?
What criteria in the data results will determine that the problem has not
recurred?
You learned:
How to identify the root cause
Why it is important
The process for proper root cause analysis
How basic quality tools can be applied to examples
Identify Problem
Team members:
Team Leader – Terry
Inspector – Jane
Worker – Tammy
Worker - Joe
Quality Eng – Rob
Engineer – Sally
Part reversed
Why?
Part reversed
Why?
Part reversed
Why?
Part reversed
Why?
Part reversed
Identify Problem
Knowing that the water is a safety hazard, the manager asks the
supervisor to have someone get a mop and clean up the puddle.
Why?
Why?
Why?
Why?
Identify Problem
Why?
Why?
Identify Problem
Team members:
Boss – Jim
Worker – Tom
Worker - Karen
Project Mgr – Bob
Admin – Sally
Why?
Procedures Personnel
Lack of worker
knowledge
Poor project plan
Poor project
mgmt skills Lack of resources
Didn’t complete
project on time
Materials Equipment
Procedures Personnel
Lack of worker
knowledge
Poor project plan
Poor project
mgmt skills Lack of resources
Didn’t complete
project on time
Materials Equipment
Why?
Why?
Identify Problem
Day 1 after cooling water system cleaning: water tests clean of pyrogens
Day 2: cooling water is saturated with pyrogens. Uh oh.
All operators and technicians reporting “possible water leaks” on all presses, all molds, all shifts…
“just in case”.
Molding operation shuts down. Operations manager nearly fired.
“Help” flying in from corporate offices and other molding plants.
Hourly conference calls to give status updates to executives.
Why?