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Through Effective
Root Cause & Corrective Action
Cedric Baker
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Goals
Create an understanding of the concept of Root Cause
analysis
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Agenda
What is Root Cause Analysis?
Why Do We Perform Root Cause Analysis?
Root Cause Analysis Philosophy
Symptom vs. Root Cause
Root Cause Analysis Process
Phase 1: Investigation
Phase 2: Analysis
Problem Solving Tools
Phase 3: Decision
Mistake Proofing
Case Study (Good RCA versus Bad RCA)
Summary (Principals or Root Cause Analysis)
Additional Resources
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What is Root Cause Analysis?
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Why do we perform
Root Cause Analysis?
Design Where a defect is found
Component
Level
often has a correlation
to the cost of the
Assembly
defect!
During
Testing
By
Customer
The goal is to
eliminate the
defect as far up
stream as possible.
At the source!
?
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Root Cause Analysis Philosophy
Phase 1: Investigation
Phase 2: Analysis
Phase 3: Decision
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Root Cause Analysis Process
Phase 1: Investigation
Purpose: Gather a factual account of the defect/failure
Be as neutral as possible
What is the problem? Where is the problem? When did the problem
Verify non-compliance Factory first occur?
Defect Supplier Day, date
Failure Design Location
Test
Environment
Runtime of system
Collect and review data for trends, process variation, and stability
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Root Cause Analysis Process
Phase 1: Investigation
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Phase 2: Analysis
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Root Cause Analysis Process
Phase 2: Analysis
Step 1
Using the factual information gathered in the investigation
phase, determine the root cause(s) by identifying potential
causes of the problem using one or more structured problem
solving tools.
Fault Tree
5 Whys
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5 Why Analysis
Phase 2: Analysis
Continue to ask why until the lowest level cause (s) are determined
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Example: Jefferson Memorial
Phase 2: Analysis
The Jefferson Memorial is deteriorating
Why?
Too much washing
Why?
Excess bird droppings
Why?
Lots of spiders to eat
Why?
Lots of gnats to eat
Why?
We leave the lights on all the time
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Problem Solving Tools
Phase 2: Analysis
Fault Tree
5 Whys
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Fault Tree Analysis
Phase 2: Analysis
The contributing causes are branched out until the root cause(s) is
reached.
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Fault Tree
Phase 2: Analysis
Bulb Fails
2.1.1 Extreme 5.1.1 Power Plant 5.1.2 Power Line 5.1.3 Connector
6.2.1 Impurities
Weather Anomaly Fails Fails Corroded
6.2.3 Exceeded
Life Expectancy
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Root Cause Analysis Process
Phase 2: Analysis
Step 2
Prioritize the potential causes and key
contributors to the causes of the problem
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Root Cause Analysis Process
Phase 2: Analysis
Step 3
Finalize the analysis by identifying the root cause(s):
Output should be a finite set of root causes showing why the incident was inevitable.
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Phase 3: Decision
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Root Cause Analysis Process
Phase 3: Decision
Step 1
Brainstorm possible solutions for corrective and preventive action.
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Mistake Proofing
Phase 3: Decision
When to use Mistake Proofing:
Human error can cause mistakes or defects to occur
The customer can make an error which affects the output
At a hand-off step in a process
Minor error early in the process causes major problems later in process
Consequences are expensive or dangerous
It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehand.
[Shingo]
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Root Cause Analysis Process
Phase 3: Decision
Step 2
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Root Cause Analysis Process
Phase 3: Decision
Step 3
Objectively Verify:
1. Each action in the implementation plan has been
carried out and completed.
2. Each solution effectively resolves root cause(s), and
eliminates or significantly reduces recurrence.
3. All documentation is complete and properly archived
4. All necessary training is complete
5. Nonconformance tracking effort is adequately closed
(SCAR, CAR, CAP, DMR, etc)
6. Consider doing a 30-60-90 day follow-up to further
ensure effectiveness of corrective/preventative actions
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Case Study
The "Case" of the Sidelined Spectacles
Situation: It's 3 p.m. and you have a 5 p.m. deadline. You are hurriedly reviewing a lengthy procedure
that needs to be amended and on the boss' desk by 5 p.m. when disaster strikes- the lens of your
glasses falls out again! What do you do?
Finding (Problem): Your glasses have broken several times within the last few weeks, which is
slowing your productivity.
Understanding the need to solve the problem immediately so that you can get on with your day as
well as to prevent it from happening again by implementing corrective action, you decide to take a root
cause analysis approach to problem solving.
Containment: Use clear adhesive tape to secure the lens in the frame.
Root Cause: The glasses keep breaking, causing me to miss deadlines.
Corrective Action: Use clear adhesive tape to secure the lens in the frame, each time they break;
ask boss for deadline extension.
REFLECTION: Why is this a poor example of root cause analysis?
The example illustrates poor root cause analysis by highlighting common mistakes that prevent clients
from identifying the true root cause and determining the proper systemic corrective action. The root
cause listed above is actually a symptom of the problem; it does not address the true problem in the
system. Also, the corrective action provided is an act of containment, not irreversible systemic
corrective action. In this example, the finding and the root cause are identical, which provides no value
to the system.
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Case Study
The "Case" of the Sidelined Spectacles
Finding (Problem): Your glasses have broken several times within the last few weeks, which is slowing your
productivity.
Short-Term Containment: Use clear adhesive tape to secure the lens in the frame.
Root Cause Analysis: Methodology: 5-Why
Restate the finding: The lens keeps falling out of my eyeglasses.
1st Why: Why does the lens keep falling out of your glasses? - The frames are damaged
2nd Why: Why are the frames damaged? - I am not storing them in the case
3rd Why: Why are you not storing them in the case? - I lost the case
4th Why: Why did you lose the case? - I am not storing the case in the same place
Corrective Action: I will keep the case in the same place by tethering the case to the desk. This will prevent the
case from being lost and I will be able to store the glasses in their case in a clear area of my desk when I don't need to
wear them.
REFLECTION: Why is this a good example of root cause analysis?
The example illustrates good root cause analysis that will allow clients to identify the true root cause and determine
the proper systemic corrective action. The root cause listed above addresses the true problem in the system. Also,
the corrective action provided is not simply an act of containment; instead it provides systemic corrective action. In
this example, the client used the "5 Why Methodology" which is a helpful tool when analyzing your root cause.
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Summary Principles of RCA
1. Define the problem
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Additional Resources
Root Cause Analysis Training and Tools
Think Reliability
http://www.thinkreliability.com/
ASQ Learning Institute
http://asq.org/training/root-cause-analysis_RCA.html
Sologic(Formerly Apollo Associated Services)
http://www.sologic.com/
Lockheed Martin Supplier Corrective Action Process
https://embastion.external.lmco.com/qis/supplier_ca/
Washington Memorial Root Cause Example
http://www.youtube.com/watch?v=IETtnK7gzlE&noredirect=1
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Credits
12 October 2011. Air University. 8 March 2012.
<http://www.au.af.mil/au/awc/awcgate/nasa/root_cause_analysis.pdf>.
Cook, Gregory and Yechiel Rosenfold. Roeing RCCA Introduction to Root Cause and Corrective
Action. n.d.
Kirupakar, B. R. Quality Risk Managment for Pharmaceutical Industry. February 2007. March
2012. <http://www.pharmainfo.net/reviews/quality-risk-management-pharmaceutical-
industry>.
Page, Jody. "Causal Analysis: Workshop Presentation." LMMFC RC RCA Worshop. Orlando, 2012.
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