Root Cause Analysis for Manufacturers

Root Cause Analysis for Manufacturers

Root cause analysis (RCA) is the process of investigating the root causes of why defects are present within a manufacturing process or end product.

Root cause analysis can be an effective modality to resolve deep-seeded issue because manufacturing professionals tend to only treat an issue’s symptoms, or even its intermediate causes, without fixing the root problem.

The problem with not digging deep enough to resolve problems is that  inattention to the finer details results in recurring difficulties that could otherwise be easily solved.

The root cause analysis approach will differ from company to company as well as from problem to problem. It may zero in on machine-specific issues across a specific OEM’s machine type. It may also be used for bottleneck analysis between departments. Or it may be used to address factory-wide defects within an enterprise.

RCA is a core component of Six Sigma, which is yet another process improvement methodology that makes for less waste and redundancy within your factory operations.

Root cause analysis 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.

Specific advantages of root cause analysis in the manufacturing sector, include:

• Cost savings because root cause analysis treats the “illness” and not the symptoms, it can reduce cost by lowering downtime, reducing defects, and improving processes.
• Automation because factories have access and insight to data more than ever before. This data can be parsed, analyzed, and contextualized to make root cause analysis consumable to other departments and factories within the same company. This acts as a force multiplier for improvement.
• Proactivity because automation through data analysis is ideally suited for the results of root cause analysis, safety, maintenance, and quality concerns can be predicted more accurately and acted upon quickly to reduce downtime.
• Realistic processes because many manufacturing companies operate with partially broken processes. Root cause analysis helps optimize processes to provide practical solutions and establish SOPs that can be followed without cutting corners or veering off the process.

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.

Root cause analyses are often conducted by process engineers in manufacturing to identify what, how, or why a precipitating event occurred.

This approach to problem-solving is usually used when the consequence involves a safety, health, environmental, quality, reliability, or production impact.

Root Cause Analysis for Manufacturers Course by Tonex

Root Cause Analysis (RCA) for Manufacturers training course will teach you the skills and knowledge 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.

Course Structure

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

• Overview of quality management processes that drive continuous improvement and audit non-conformities.
• An overview of the Root Cause Analysis (RCA)
• Similarities and differences between Corrective and Preventative Action (CAPA) and RCA
• proactive activities that support PDCA approach (Plan Do Check Act) to achieve continuous improvement.
• 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/Fishbone Diagram), Failure Mode Affect Analysis (FMEA), Event Tree Analysis (ETA), Fault Tree Analysis (FTA) and others.

Course Agenda

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
• Brainstorming
• 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 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 2: Keep Asking Why- Discovering Relationships between Various Root Causes of a Single Nonconformance,

Activity 2: Working with 5 Whys Method

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 3: Using Easily Understood Visual of the Potential Root Causes of a Nonconformance
• Activity 3: Brainstorming – Working with Fishbone Diagra

Overview of Other Approaches to Root Cause Analysis

• Failure Mode Affect Analysis (FMEA)
• Process vs. Design FMEA
• Event Tree Analysis (ETA)
• Fault Tree Analysis (FTA)
• 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

Workshop 2: Working with 8D 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