FICCI

CE

Root cause analysis

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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.

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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.

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Possible root causes for non conformance/ defects

Machine factors Inadequate process capability Incorrectly designed tooling Worn tools, jigs or dies Poor maintenance Equipment effected by environmental factors such as heat, humidity etc.

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Possible root causes...

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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Possible root causes...

Men factors Incorrect knowledge of setting up machines Careless operator and inadequate supervision 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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Possible root causes...

Method factors Inadequate process controls Non availability of proper test equipments Test equipment out of calibration Vague inspection/ testing instructions Inspectors do not possess the necessary skill

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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.

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Cause & Effect diagram - Major and subsidiary causes

Material
Assemblies

Methods
Procedures

Environment
Noise level Temperature

Consumables Components Suppliers Accounting Policies Lighting

Humidity

Quality
Variability Training Experience Technology Tooling Attitude Skill Fixtures Gauging Counting Instruments Tests

Men

Machine

Measurement

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Example of Cause & Effect diagram - Low operating profit

Material
High lead time poor review system High inventory Poor quality of vendors Poor QC Poor MIS High variation Poor Lighting

Methods
Inadequate process control

Environment
High Noise level

Heat

Lack of Experience

Inadequate Training

Inadequate Instruments

Low operating profit

Old machines

Poor Maintenance
Low motivation Frequent breakdowns

No SPC

Inadequate measurement

Men

Machine

Measurement

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Click on the boxes to enter your cause & effect

Material Methods Environment
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Men

Machine

Measurement