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FICCI CE
Root cause analysis
FICCI CE
Root cause analysis
In any organization numerous problems exist in all facets of its activities. The
efficiency and survival of the organization depends on how promptly these problems
are recognized and their root causes are isolated and eliminated.
FICCI CE
Root cause analysis
A systematic analysis of each potential problem area should be carried out
to recognize the root causes which are responsible for creating the problem.
Such analysis is called Root Cause Analysis.
FICCI CE
Possible root causes for non conformance/ defects
Machine factors
• Inadequate process capability
• Incorrectly designed tooling
• Worn tools, jigs or dies
• Poor maintenance
• Equipment effected by environmental factors such as heat, humidity etc.
FICCI CE
Possible root causes...
Material factors
• Use of untested materials
• Mix-up of materials
• Substandard material accepted on concession because of non-availability
of correct material
• Inconsistency in specifications on the part of vendors
FICCI CE
Possible root causes...
Men factors
• Incorrect knowledge of setting up machines
• Careless operator and inadequate supervision
• Undue rush by the operator to achieve quality targets
• Lack of understanding of drawing instructions relating to a process
• Operator does not posses requisite skill for operating machines
FICCI CE
Possible root causes...
Method factors
• Inadequate process controls
• Non availability of proper test equipments
• Test equipment out of calibration
• Vague inspection/ testing instructions
• Inspectors do not possess the necessary skill
FICCI CE
Cause and effect diagram
Cause and effect diagram (also known as ishikawa diagram or fishbone
diagram) is an analysis tool to analyze many potential or actual causes of
a problem in a systematic way. It is a very effective way of improving
the quality of the product or service.
FICCI CE
Cause & Effect diagram - Major and subsidiary causes
Material Methods Environment
Men Measurement Machine
Quality
Assemblies
Components
Suppliers
Consumables
Procedures
Policies
Accounting
Noise level
Humidity
Temperature
Lighting
Training
Experience
Skill
Attitude
Variability
Tooling
Fixtures
Technology
Instruments
Gauging
Counting
Tests
FICCI CE
Example of Cause & Effect diagram - Low operating profit
Material Methods Environment
Men Measurement Machine
Low
operating
profit
High lead time
High inventory
Poor quality
of vendors
poor review
system
Inadequate
process control
Poor MIS
Poor QC
High Noise level
Heat
Poor Lighting
Inadequate
Training Lack
of Experience
Low
motivation
High
variation
Poor
Maintenance
Frequent
breakdowns
Old machines
Inadequate
Instruments
Inadequate
measurement
No SPC
FICCI CE
Click on the boxes to enter your cause & effect
Material Methods Environment
Men Measurement Machine
click
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