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Similar to PRIZ Academy - Root Cause Analysis (RCA) Quality Assurance with PRIZ
PRIZ Academy - Root Cause Analysis (RCA) Quality Assurance with PRIZ
- 1. “Fix the cause,not the symptom” Steve Maguire PRIZ Guru Engineering Thinking Platform Root Cause Analysis (RCA): Quality Assurance with PRIZ PRIZ Academy - Webinar - Apr 23, 2025
- 2. Quality is Everyone'sResponsibility Quality Must Be Built Into Every Stage Integrate Quality From Day One, Not as an Afterthought Quality is a Continuous Journey, Not a Destination QUALITY ASSURANCE IS EVERYONES JOB Every Process Touch Point Shapes Quality Outcomes
- 3. DEFINITION, GOALS &VALUES Systematic activities that ensure processes consistently produce products or services that meet quality requirements—focusing on preventing defects. “Are we doing the process right so defects never happen?” QA Main Goals Prevent Defects Build quality in, not inspect it out Ensure Consistency Standardize for predictable results Drive Improvement Continuously raise performance QA Main Values Protect Brand & Trust Consistent quality -> loyal customers & strong reputation Reduce Costs Less rework, scrap, and downtime -> higher margins Excellence Culture Accountability & continuous learning Paradigm Shift: Quality is always at risk — unless it's intentionally assured.
- 4. TRADITIONAL QA (INSPECTIONCENTRIC) Relies on inspections and final-stage testing Detects problems after they occur Often treats symptoms, not causes Leads to rework, delays, and frustration It’s too late when the product is already out the door.
- 5. MODERN QA: FROMDETECT-AND-FIX to PREDICT-AND-PREVENT Quality Assurance begins at system design phase Proactive prevention outperforms reactive detection Involves cross-functional collaboration Built-in continuous improvement Successful QA is proactive and systematic, powered by rigorous Root-Cause Analysis.
- 6. WHAT IS ROOTCAUSE Traditional definition The fundamental reason for the occurrence of the problem Dead End Practical definition A root cause is a source of a defect such that if it is removed, the defect is decreased or eliminated. Helpful 6
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- 8. HUMAN ERROR HELPEDQA Traditional QA Issue Multiple failure of electrical test Findings Metal layer was deposited with the thickness of 20% more than required Reason Human error during recipe setup Conclusion Scrap all affected wafers Perform additional training to engineers Modern QA - PRIZ Process Issue Electrical failure when the metal layer thicker on 20% RCA Metal failure analysis revealed an undercut Overetching occurred during wet cleaning process that removes metal residue Root cause: Strong exothermic reaction between metal and acid solution Quality Risk & Quality Assessment Similar defects were identified in standard thickness samples Optimized acid solution parameters (concentration and temperature) to eliminate overetching Field: Manufacturing – microchip production
- 9. HUMAN ERROR HELPEDQA Acid Solution Acid Solution
- 10. PRIZ - ENGINEERINGTHINKING PLATFORM https://www.priz.guru
- 11. https://www.priz.guru/ https://www.linkedin.com/company/priz-guru https://twitter.com/PrizGuru CONTACT Alex: +1 (778)668-1811 • alex@priz.guru Anatoly: + (972) 54-333-9825 • anatoly@priz.guru