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Root cause analysis

Also known as fish-bone diagram

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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.

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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

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Machine factors

• Inadequate process capability• Incorrectly designed tooling• Poor maintenance• Equipment effected by environmental factors such as heat,

humidity etc.

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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

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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

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Method factors

• Inadequate process controls• Non availability of proper test equipments• Test equipment out of calibration• Vague inspection/ testing instructions

Cause and effect diagram

Cause and effect diagram (also known as ishikawa diagram or fishbone diagram) is an analysis tool to analyze many potential or actual causes of a problem in a systematic way. It is a very effective way of improving the quality of the product or service.

Cause & Effect diagram - Major and subsidiary causes

Material Methods Environment

Men MeasurementMachine

Quality

Assemblies

Components

Suppliers

Consumables

Procedures

Policies

Accounting

Noise level

Humidity

Temperature

Lighting

Training

Experience

Skill

Attitude

Variability

Tooling

Fixtures

Technology

Instruments

Gauging

Counting

Tests

Example of Cause & Effect diagram - Low operating profit

Material Methods Environment

Men MeasurementMachine

Lowoperating

profit

High lead time

High inventory

Poor quality of vendors

poor review system

Inadequate process control

Poor MIS

Poor QC

High Noise level

Heat

Poor Lighting

InadequateTraining

Lackof Experience

Lowmotivation

Highvariation

PoorMaintenance

Frequentbreakdowns

Old machines

InadequateInstruments

Inadequatemeasurement

No SPC

Click on the boxes to enter your cause & effect

Material Methods Environment

Men MeasurementMachine

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