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Continuous Improvement Toolkit
Published in Tina Kanti Agustiady, Elizabeth A. Cudney, Building a Sustainable Lean Culture, 2023
Tina Kanti Agustiady, Elizabeth A. Cudney
Root cause analysis is the process of finding and eliminating the cause, which would prevent the problem from returning. Only when the root cause is identified and eliminated can the problem be solved. Root cause analysis uses the D-M-A-I-C philosophy as a guide. The steps to root cause analysis are as follows:Define the problemMap the processGather dataSeek for root causes through fishbone diagrams/cause and effect diagramsVerify root causes with dataDevelop solutions and prevention steps including costs and benefitsPilot implementation plansImplementControl utilizing a monitoring plan and process metricsIdentify lessons learned
Data Collection and Analysis
Published in James William Martin, Lean Six Sigma for the Office, 2021
A Pareto chart compares several discrete variables or categories to their occurrence frequency or total count. Figure 5.13 uses the data from Figure 5.5 to show the occurrence frequency of several process issues. The Pareto chart shows the number of process breakdowns in decreasing order by issue. The category NVA activities has the highest total number of process issues, and the waiting has the second highest frequency. Because occurrence frequency is clearly shown from the highest to lowest levels, Pareto charts are useful for focusing a team on the most impactful issues for subsequent root cause analysis. Pareto charts are created at this first level and then at second and third levels. As an example, Figure 5.13 could be broken down to a next lower level by analyzing the reasons for the NVA or waiting. In summary, Pareto charts are useful for investigating the root causes of a process problem and helping to clearly communicate them.
Painting Problems
Published in Rose A. Ryntz, Philip V. Yaneff, Coatings Of Polymers And Plastics, 2003
Root cause analysis involves the determination of the basic or underlying cause of a defect or problem and the providing of evidence that it is the cause. We know that craters are caused by contaminants, but the root cause of a cratering outbreak may be poor tote cleaning, a contaminated drum, overreduction of the paint so that it flows too much, or a batch of paint that is unusually sensitive to contaminants that always are present. It may be clear that a defect is a solvent pop, but the root cause could be an application problem that causes fat edges or sags that, in turn, lead to pops. Root cause analysis often takes a lot of detective work, experimentation, and documentation. Sometimes it takes longer than it did to solve the problem. The point is that if the true root cause has been identified and removed or fixed, the problem or defect should not occur again.
Determining which of the classic seven quality tools are in the quality practitioner’s RCA tool kit
Published in Cogent Engineering, 2023
A Root Cause Analysis (RCA) is performed to identify the cause of problems and includes actions to establish a definition of the problem, analyze the problem, and find the cause of the problem, so that the problem can be prevented from occurring again (Lee et al., 2018). There are many reasons why an RCA may be needed. For example, Harjac et al. (2008) investigated corrosion of the walls of absorber towers and Cournoyer et al. (2013) investigated cut, torn, and pinched gloves in a safety glove box for a process that involved radioactive material. Alexa and Kiss (2016) describe an RCA to identify the root causes of damaged packaging and Darekar et al. (2013) explain the details of an investigation into the leakage of a vehicle fuel line.