FICCI CE Root cause analysis In any organization numerous problems exist in all facets of its activities. The efficiency and survival of the organization depends on how promptly these problems are recognized and their root causes are isolated and eliminated.
FICCI CE Root cause analysis A systematic analysis of each potential problem area should be carried out to recognize the root causes which are responsible for creating the problem. Such analysis is called Root Cause Analysis.
Possible root causes for non conformance/ defects
FICCI CE Machine factors • Inadequate process capability • Incorrectly designed tooling • Poor maintenance • Equipment effected by environmental factors such as heat, humidity etc.
FICCI CE Material factors • Use of untested materials • Mix-up of materials • Substandard material accepted on concession because of non- availability of correct material • Inconsistency in specifications on the part of vendors
FICCI CE Men factors • Incorrect knowledge of setting up machines • Undue rush by the operator to achieve quality targets • Lack of understanding of drawing instructions relating to a process • Operator does not posses requisite skill for operating machines
FICCI CE Method factors • Inadequate process controls • Non availability of proper test equipments • Test equipment out of calibration • Vague inspection/ testing instructions
Cause and effect diagramCause and effect diagram (also known as ishikawa diagram orfishbone diagram) is an analysis tool to analyze many potential oractual causes of a problem in a systematic way. It is a veryeffective way of improving the quality of the product or service.
Cause & Effect diagram - Major and subsidiary causes Material Methods Environment Procedures Noise level Assemblies TemperatureConsumables Humidity Components Accounting Suppliers Lighting Policies Quality Variability Instruments Training Experience Tests Technology Tooling Attitude Gauging Skill Fixtures Counting Men Machine Measurement
Example of Cause & Effect diagram - Low operating profit Material Methods Environment Inadequate High Noise level High lead time process controlpoor review Heat system High inventory Poor QC Poor quality of vendors Poor Lighting Poor MIS Low operating High profit Inadequate variation Instruments Inadequate Training Lack of Experience Old machines Poor No SPC Maintenance Low Frequent Inadequate motivation breakdowns measurement Men Machine Measurement
Click on the boxes to enter your cause & effectMaterial Methods Environment Click to enter click Men Machine Measurement