Group Discussion Addressing the Key Points of Root Cause Analysis
Question 2: Is action dependent on the cost of the part?
Question 3: Why is it important to treat each problem like a Golden Nugget?
Question 4: Is best-in-class or simply beating your competitor’s quality levels good enough?
Question 1: How many times does the same problem have to occur before action is taken?
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.)
Without using data to find the “true problem,” we suffer the consequences of:
The key sources that contribute most significantly to the problem
The relationship among the wide variety of possible contributors
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
Take special note of causes that appear repeatedly.
Keep asking “Why?” until you get to the root of the problem.
Plan at least (2) counter measures to prevent recurrence.
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