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#8 Root Cause Analysis

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suman_purumandla

tools and techniques required for root cause analysis

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Root Cause Analysis
Group Discussion Addressing the Key Points of Root Cause Analysis ,[object Object],[object Object],[object Object],[object Object]
Problem Escapes and the Rule of 10 Defect Found at: Cost to the Company: Impact to the Company: Own Process Very Minor Next Process Minor Delay End of Line Rework Reschedule of Work Final Inspection Significant Rework Delay in Delivery Additional Inspection Customer Warranty Cost Admin. Cost Reputation Loss of Market Share $1 $10 $100 $1,000 $10,000
The “True” Problem Must Be Understood Before Action Is Taken (cont.) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Symptom Approach vs. Root Cause ,[object Object],[object Object],[object Object],[object Object],Addressing the Wrong Problem “ Old Mindset” “ New Mindset” ,[object Object],[object Object],[object Object],[object Object]
Philosophy of Root Cause Methodology ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Fundamental Elements
Root Cause Analysis Definition ,[object Object]
Process Definition ,[object Object]
Root Cause Tools ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Generating Ideas Prioritizing Data or Action Action Planning ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Finding Patterns and Relationships Examining Results Grouping Ideas ,[object Object],[object Object],[object Object],[object Object],(i.e.: Red X)
Brainstorming Guidelines ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
The purpose is to understand: ,[object Object],[object Object],Cause-and-Effect Diagram
or Fishbone or Ishikawa Diagram Cause-and-Effect Diagram Other (on every diagram) Causes Effect Materials Machinery Policies Plant/Equipment People Procedures Effect Man/Woman Methods Problem Reason Counter Measure
Cause-and-Effect Diagram Eliminated symmetry, added notch Materials Machinery Man/Woman Methods Cannot Load Software on PC Power Interruption Bad Disk Diskette Missing Wrong Type Disk Don’t Have Mouse Inserted Disk Wrong Instructions Are Wrong Not Following Instructions Cannot Answer Prompt Question Graphics Board Incompatible Other Instructions Were Not Clear Not Enough Free Memory Hard Disk Crashed Upside Down Backward
Tips for effective Cause-and-Effect Diagrams ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Tips for effective Cause-and-Effect Diagrams ,[object Object],[object Object],[object Object],[object Object]
5 Why’s A questioning technique for getting beyond symptoms and uncovering root causes.
5 Why’s (cont.) What’s happening that shouldn’t be? Why is it happening? Problem 1 2 3 4 5 Why is that? Why is that? Why is that? Why is that? C A U S ES Caution: If your last answer is something you cannot control, go back to previous answer
[object Object],[object Object],[object Object],Flat Tire in Garage Nails on garage floor Swept up nails Example: 5 Why’s
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Flat Tire in Garage Nails on garage floor Box on shelf split Box got wet Rain through hole in garage roof Rain happens Example: 5 Why’s
Keys to Success ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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#8 Root Cause Analysis

  • 2.
  • 3. Problem Escapes and the Rule of 10 Defect Found at: Cost to the Company: Impact to the Company: Own Process Very Minor Next Process Minor Delay End of Line Rework Reschedule of Work Final Inspection Significant Rework Delay in Delivery Additional Inspection Customer Warranty Cost Admin. Cost Reputation Loss of Market Share $1 $10 $100 $1,000 $10,000
  • 4.
  • 5.
  • 6.
  • 7.
  • 8.
  • 9.
  • 10.
  • 11.
  • 12. or Fishbone or Ishikawa Diagram Cause-and-Effect Diagram Other (on every diagram) Causes Effect Materials Machinery Policies Plant/Equipment People Procedures Effect Man/Woman Methods Problem Reason Counter Measure
  • 13. Cause-and-Effect Diagram Eliminated symmetry, added notch Materials Machinery Man/Woman Methods Cannot Load Software on PC Power Interruption Bad Disk Diskette Missing Wrong Type Disk Don’t Have Mouse Inserted Disk Wrong Instructions Are Wrong Not Following Instructions Cannot Answer Prompt Question Graphics Board Incompatible Other Instructions Were Not Clear Not Enough Free Memory Hard Disk Crashed Upside Down Backward
  • 14.
  • 15.
  • 16. 5 Why’s A questioning technique for getting beyond symptoms and uncovering root causes.
  • 17. 5 Why’s (cont.) What’s happening that shouldn’t be? Why is it happening? Problem 1 2 3 4 5 Why is that? Why is that? Why is that? Why is that? C A U S ES Caution: If your last answer is something you cannot control, go back to previous answer
  • 18.
  • 19.
  • 20.