Root Cause Analysis for Manufacturers
Root Cause Analysis (RCA) for manufacturers is useful because when the steps of the manufacturing process are extensive and complex, it helps to have a way to trace issues straight to the origin.
Manufacturers can save valuable time and resources by optimizing their troubleshooting system and implementing Root Cause Analysis basics.
Root Cause Analysis is the process of finding the basic underlying cause for an effect we observe or experience. In the context of failure analysis, RCA is used for finding the root cause of frequent machine malfunctions or a big machine breakdown.
In the manufacturing sector, this is particularly significant. RCA can help manufacturers increase revenue. Defects, downtime and maintenance all affect how much money you bring in, and the longer you’re out of commission, the more you lose. Reducing the occurrence of these issues keeps your company active, so you can maintain your revenue stream.
It’s also germane to recognize that he solutions created by Root Cause Analysis can last for years. You can develop clear, step-by-step processes that work every time and offer you incredible ease of use. Avoid struggling with producing a new solution every time a malfunction occurs — plug in a tried and true formula, instead.
Additionally, manufacturers can detect safety hazards before they become a reality and predict deviations in product quality, fixing those issues before they reach consumers. Even without an automated solution, you still gain the advantage of an arsenal of data you can use to stop problems in their tracks.
Historically, many manufacturing professionals only treat an issue’s symptoms, or even its intermediate causes, without fixing the root problem — this inattention to the finer details results in recurring difficulties that could otherwise be easily solved.
When the steps of your manufacturing process are extensive and complex, it helps to have a way to trace issues straight to the origin. You can save valuable time and resources by optimizing your troubleshooting system and implementing root cause analysis basics, using tools such as:
- The Five Whys – an investigative method used to drill down on a particular problem. “Why?” is asked repeatedly until a core problem is identified.
- Failure Modes effect analysis (FMEA) – highlights failures within a particular system. You can use this tool at any particular and consists of two main components: Failure Mode and Effect Analysis.
- Scatter Diagram –also known as Scatter Plots, are visual representations of a relationship between two sets of data. It is a simple quantitative method of testing correlation between variables.
- Fishbone Diagram – a tool widely used to analyze complex problems. Also known as a Cause-and-Effect Diagram, groups potential causes of a particular problem into subcategories linking back to the main problem being investigated.
RCA is a core component of Six Sigma, which is yet another process improvement methodology that makes for less waste and redundancy within factory operations.
This concept is also a major player in LEAN manufacturing. Like Six Sigma, this system focuses on waste reduction, fewer process delays and less excess inventory.
One of the most beneficial elements of RCA is how it can combine with numerous other process improvements to create a faster, more productive system than before.
Root Cause Analysis for Manufacturers Course by Tonex
Root Cause Analysis (RCA) for Manufacturers training course will teach attendees to identify the cause of a problem, solve it, and prevent it from occurring again. RCA saves manufacturers and system integrators valuable resources, time, and money by optimizing their troubleshooting system and implementing root cause analysis basics.
Root cause is the fundamental, underlying reason for a problem. Many manufacturers might only treat an issue’s symptoms, or even its intermediate causes, without fixing the root problem. RCA helps with process improvement and makes improvement for less waste and redundancy within your operations.
Root Cause Analysis (RCA) course will enable participants to understand root cause analysis and the process of investigating the root causes of why defects are present within a manufacturing process or product and determine what can be done to solve or prevent them. Participants will gain a working knowledge of RCA process, methodologies, tools, and best practices.
Who Should Attend?
This course is designed for technicians, engineers, testers, integrators, operators, maintenance, analyst, quality, reliability, safety, process employees with little or no Root Cause Analysis (RCA) experience. The course is also useful for those who have experience with RCA but have never had any formal training on the standard.
Lectures, hands-on and problem solving practices using simple tools and methodologies. The course is designed to provide the participants with tools and best practices to analyze complex systems (system manufacturing, integration and operation) to identify the root causes of problems.
- Comprehensive RCA Training Course Manual
- RCA Cheat Sheet
- Tonex’s Root Cause Analysis Tools, Techniques and Templates (Excel Tools and RCA Templates Provided)
- Core of Problem Solving and Corrective Action
What You Will Learn
- An overview of the Root Cause Analysis (RCA).
- A summary of RCA tools and applications.
- An overview of problem solving techniques.
- RCA process, methods, their strength, and their effectiveness in dealing with the complexity of complex manufacturing and system integration/operation processes.
- Using RCA tools and methodologies including Fishbone diagram, 5-Whys, Cause and Effect Analysis, Event Tree Analysis (ETA), Fault Tree Analysis (FTA), Failure Mode Affect Analysis (FMEA) and others.
Fundamentals of Root Cause Analysis (RCA)
- Root Cause Analysis for Manufacturers
- Benefits of Root Cause Analysis
- How to Conduct Root Cause Analysis
- Manufacturing Problem Solving Models
- Root Causes and Realistic Solutions
- Core Principles of Operational Efficiency
- Analytical and Creative Thinking
Root Cause Analysis (RCA) Methods
- Working with Qualitative RCA Tools
- Fishbone Diagram: Cause and Effect Diagrams 5 Why, Concentration Diagrams
- Working with Quantitative RCA Tools
- Capability Analysis, Control Charts, MSA, and Regression Analysis
- Corrective Action Strategies
- Correlating Process and Product Variables, and Poke Yoke
- Control Charts
- Cross-functional Team Building
- The Basic Method
- Basic RCA Procedure
- Defining Area of Concerns
- Collect all Relevant Data about the Problem
- Analyze the Information for Evidence of all Root Causes
- Develop or Recommend Strategies for Handling the Problem
- Implement Solutions as Needed
- Case Study 1
- Activity 1: Working with RCA Methods
The Fishbone Diagram
- Ishikawa Diagram
- Fishbone Diagram: “Cause and Effect” Diagram
- Manufacturing, System Integration and Operation Issues
- Ways to Examine the Causes and Effects
- Catalysts and Gleaning Ideas
- Fishbone Procedure
- Inefficiency in your Manufacturing and Operational Structure
- Identifying Root Cause to the Defects
- Finding Intermediate Causes
- Variation in the Process
- 6M’s (5 M’s and 1 P)
- Six Elements Contribute to Variation in a Process
- Machine, Material, Method, Measurement, Mother Nature “Environmental” and Man (People)
- Case Study 2: Using Easily Understood Visual of the Potential Root Causes of a Nonconformance
- Activity 2: Brainstorming – Working with Fishbone Diagram
The Five Whys (5 Whys)
- The Five Whys Technique
- Benefits of the 5 Whys
- An Effective Method for Determining Root Causes
- To Identify the Root Cause of a Problem
- Determine the Relationship between Different Root Causes of a Problem
- Easy to Complete without Statistical Analysis
- When Is 5 Whys Most Useful?
- When Problems Involve Human Factors or Interactions
- How to Complete the 5 Whys
- Case Study 3: Keep Asking Why- Discovering Relationships between Various Root Causes of a Single Nonconformance,
- Activity 3: Working with 5 Whys Method
- Root Cause Analysis (RCA) and the 8D Corrective Action Process
- Effective problem-solving method is the eight disciplines (8D) model,
- Identifying, Correcting, and Eliminating Recurring Problems
- 8D for Product and Process Improvement
- 8D approach and Permanent Corrective Actions based on Statistical Analysis of the Problem
- Source of the Problem by Determining its Root Causes
- Case Study 4: Root Cause Analysis and the 8D Corrective Action Process, Real-life Experience with Actual Examples from Manufacturing, Engineering, System Integration and Operation
- Activity 4: Working with 8D
Overview of Other Approaches to Root Cause Analysis
- Event Tree Analysis (ETA)
- Fault Tree Analysis (FTA)
- Failure Mode Affect Analysis (FMEA)
- Events and Causal Factor Analysis
- Change Analysis
- Barrier Analysis
- Management Oversight and Risk Tree
- Kepner-Tregoe Problem Solving and Decision Making
Workshop 1: Apply RCA Techniques to a Real Problem Defined
- Problem Definition
- Factor that Caused a Nonconformance
- The Process
- Problem Identification Components
- Defect Creation
- Physics of Failure
- Human Factors
- Life Cycle Gaps
- Hidden Failures
- Production and Equipment Failure
- Reliability Engineering and Failures
- Identifying Possible Causes
- Eliminating the Underlying Cause(s)
- Preventing Reoccurrence
- DeBono’s Six Hats
- Data Collection and Data Analysis Tools
- Analysis of Human Errors
- Management and Organizational Issues
- Policy Issues
Root Cause Analysis for Manufacturers