Root cause analysis

Root Cause Analysis: Uncovering and Solving Problems at Their Source

Root Cause Analysis addresses a question many businesses face:

Why Do Problems Keep Coming Back?

Before we get the answer to this, let’s walk through a common situation that companies usually face.

Businesses often encounter situations where the manufacturing line keeps producing defective products. The situation becomes more intangible when every time experts solve one issue, another pops up.

How can a business be productive if it’s held in this never-ending, frustrating game of whack-a-mole? It’s costly, time-consuming, and downright exhausting.

If you have been witnessing such a situation, you would think,

“What if there was a way to stop this cycle for good?”

That’s where Root Cause Analysis or RCA comes in.

RCA is your ultimate detective tool. It helps you:

dive deep into problems

uncover their true causes

implement lasting solutions

What Is Root Cause Analysis?

RCA is an integral part of lean management that contributes to Kaizen or Continuous improvement.

Root Cause Analysis is a systematic problem-solving approach that helps businesses identify the underlying causes of problems. Rather than just addressing the symptoms, it’s a lean tool that successfully finds the source and reveals the main reason behind an issue.

Once the root cause is identified, organizations find themselves in a better position to address the issue right at the grassroots level. The solutions or corrective actions ensure the same issue never arises in the future.

Roots of Root Cause Analysis

RCA originates from a field focused on quality improvement and problem-solving. That’s Total Quality Management.

Root Cause Analysis is a critical part of TQM problem-solving processes, ultimately contributing to the continuous improvement initiatives of the organization.

It is critical to TQM’s problem-solving processes and contributes to continuous organizational improvement initiatives.

Why Is RCA Done?

Organizations use Root Cause Analysis for:

Enhance Efficiency

Eliminate disruptions that slow down operations and identify sources of wasted resources.

Reduce Costs

Address root causes to prevent costly repeat failures.

Improve Quality

Ensure consistent product or service delivery.

Foster Innovation

Uncover insights that lead to better processes, products, and systems.

Benefits of Root Cause Analysis

Quality, process consistency, and improved efficiency will surely strike and benefit your business after using RCA to tackle issues. But you’ll be surprised to learn more about the advantages of root cause analysis in manufacturing and other sectors after studying the breakdown below.

Long-Term Solutions	Get permanent solutions for recurring problems.
Higher Productivity	Enjoy reduced downtime and free up resources.
Cost Savings	Lesser problems mean fewer supply and quality problems and lots of cost savings.
Better Morale	Promote empowering teams with effective problem-solving attitudes.
Improved Customer Satisfaction	Satisfied customers = better retention, more business! Deliver high-quality products and services to enjoy positive feedback from customers.

RCA Works
Let Numbers Do the Talking

1. Cost Savings:

RCA can save companies a lot of money—up to 30% in operational costs. How? By reducing wasted materials and fixing recurring problems. And guess what? The need to rework also drastically reduces. This all contributes to better quality products made at a lower cost and delivered on time to customers.

2. Better Quality:

RCA helps reduce product defects by approx 50%! Isn’t it huge? Won’t you rely on RCA for higher-quality products and happier customers? In certain industries tolerance can be narrowed on specifications after identifying the source of performance variations and a better understanding of product performance and applications.

3. More Efficiency:

Imagine your company performing at a boosted productivity rate of 25% after RCA! That’s the transformation RCA brings—Reduced downtime and streamlined process.

4. Improved Safety:

Workplace accidents are horrible! The good news, however, is that they can be dropped by 40% with RCA applied to incidents and workplace hazards. It helps find and fix potential hazards, sources of unsafe conditions, and behaviours. Once these have been identified hazards can be eliminated and it’s much easier to create a safer environment for employees.

Tools for Root Cause Analysis

Right tools for the right job! RCA can’t be done without utilizing the tools and techniques that lead you to uncover the real cause.

1. The 5 Whys Simple, Yet Powerful

The 5 Whys is a straightforward method where you ask “Why?” repeatedly until the root cause of a problem is revealed. This method of root cause analysis works best in situations where the problem is not technical but quite straightforward.

Understanding 5 Whys Through A Real-Life Example

Fixing Machine Downtime

Let’s say your production line grinds to a halt.

Here’s how the 5 Whys can help:

1. Why did the machine stop?

A fuse blew in the motor.

2. Why did the fuse blow?

The motor overheated.

3. Why did the motor overheat?

It wasn’t adequately lubricated.

4. Why wasn’t it lubricated?

The maintenance schedule was skipped.

5. Why was the schedule skipped?

There aren’t enough maintenance staff.

Root Cause Identified: Staffing shortages in maintenance.

Tips for Using the 5 Whys Effectively

Engage the right people.
Stay objective, and focus on facts.
Avoid assumptions.
Avoid stopping at surface-level answers.

2. Fishbone Diagram A Visual Way to Diagnose Problems

The Fishbone Diagram is an excellent tool for tackling complex problems with multiple factors. Also known as a Cause-and-Effect Diagram, the Fishbone Diagram focuses on categorization. It categorizes potential causes into groups like People, Methods, Machines, Materials, and Environment.

Example of Root Cause Analysis Using Fishbone Diagram

Reducing Product Defects

For instance, your team is dealing with recurring product defects. Here’s how using a Fishbone Diagram helps you:

People: Insufficient training for operators.

Methods: Inconsistent quality control procedures or specifications defined correctly.

Machines: Malfunctioning equipment with repeated breakdowns.

Materials: Poor-quality raw materials with variations in quality.

Environment: Inadequate lighting on the production floor.

Result? It narrows down to the problems in every category. Solving these problems will ultimately create an error-free working environment.

Tips for Creating a Great Fishbone Diagram

To make the best use of the Fishbone Diagram, never ignore these tips.

Brainstorm with a Diverse Team

Different perspectives contribute to better insights.

Prioritize Likely Causes

Focus on the most impactful areas.

Keep It Clear

Use simple language and clear categories.

Other Root Cause Analysis Tools & Techniques

5 Whys and the Fishbone Diagram aren’t the only tools for RCA. Other include:

Fault Tree Analysis

This technique maps out causal chains using a tree structure. FTA is considered Ideal for high-risk industries.

Pareto Analysis (80/20 Rule)

Identifies the top 20% of causes that lead to 80% of problems. It works great when prioritizing efforts.

Affinity Diagrams

This tool groups large datasets into manageable categories. Perfect for spotting patterns.

Failure Mode and Effects Analysis

It’s a proactive method to identify potential failures, their effects, and their severity. FMEA is perfect for complex processes such as in manufacturing or healthcare.

DMAIC

This structured Six Sigma methodology stands for Define, Measure, Analyze, Improve, and Control. It’s ideal for improving process efficiency and reducing variability.

Kepner-Tregoe Analysis

A systematic four-step process is great for resolving multifaceted issues. It does so by breaking the issues into manageable components.

Barrier Analysis:

Evaluates barriers or safeguards that could prevent an issue. It works best in safety-critical environments like aviation.