Tactics for Root Cause Analysis

T

toniriazor

Involved In Discussions
#1
#1
Hello

From a long time I was thinking to open this thread. The idea is to exchange knowledge for different ways when it comes to root cause analysis and problem solving.

Most of us here work in environments where we encounter issues every day and have to solve them following certain approaches. Learning is endless.

Long time ago I found a post here in the forum where it was written that a Japanese professor used to gather team of 5 people and send them for an hour to observe a mfg. process. Afterwards everyone had to write what he/she had seen during this one hour of time. At the end all 5 people had seen different things. I really liked this method and understood how many different approaches actually one can use to find a problem and what we all see is different.

I will share some of the methods I use and hope you guys can share too your way of handling issues. So I most often rely on:

1 ) observing at least 10 full cycles of mfg. line or a process, because people tend to return to their habits shortly after I appear on the line to investigate. Then I can often see what really is wrong and where is the problem.
2 ) Always try to have friendly talks with operators on the line and most of the time they are the key to finding the root cause.
3 ) Another method I use from time to time is to check cameras ( I really don't like this one ) but I often see how careless people could be especially on night shifts when management is out of factory. Then I can use what I had seen on the cameras to ask proper questions the operators which worked and skip key process steps.
4 ) Trying to manufacture a product by myself with current standard (often see so many gaps) including process design issues and product design issues as well.

Thank you.
 
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O

Orlando Labrada

Registered
#2
#2
Hi, I share with you the Number 1, 2 and 3. I think 4 is a good one since I always look how to not depend to human to do the things right, correctly or as expected.

To find a root cause to a certain level, I always look how to not depend to operator.

Currently, we have issues with wrong-incorrect parameters set up to machine. Units were processed with wrong parameters and line clearance approved. So, anyone does not detected it at the beginning of the work order, it was detected later. So instead of be a failure of employee to set up a parameter, why does the machine does not stop by a change on their output? Is there a possibility to have alarm limits so robust enough to detect a wrong parameter?. So I think that Root Cause that units were processed with other parameters is because limits are not robust enough. This is not a final decision, I am working on it to decide if took it as RCA or keep it looking.

The previous was an example.
 
T

toniriazor

Involved In Discussions
#4
#4
Orlando Labrada said:
Hi, I share with you the Number 1, 2 and 3. I think 4 is a good one since I always look how to not depend to human to do the things right, correctly or as expected.

To find a root cause to a certain level, I always look how to not depend to operator.

Currently, we have issues with wrong-incorrect parameters set up to machine. Units were processed with wrong parameters and line clearance approved. So, anyone does not detected it at the beginning of the work order, it was detected later. So instead of be a failure of employee to set up a parameter, why does the machine does not stop by a change on their output? Is there a possibility to have alarm limits so robust enough to detect a wrong parameter?. So I think that Root Cause that units were processed with other parameters is because limits are not robust enough. This is not a final decision, I am working on it to decide if took it as RCA or keep it looking.

The previous was an example.
Click to expand...
Hello, try to modify software of machine or contact machine manufacturer so you could have as a job-starter option the OK values of the product. Meaning operator has to carry out certain checks and measurements and input them in the software as OK and NOK. If NOK machine will not start. Include this in your control plan and operation standard. Negative side of it is that when they learn the values by heart they just put them without doing the measurements and checks, but this discipline issue can be improved by frontman or leader of the production line with continuous work with the people on the machines.
 
O

outdoorsNW

Quite Involved in Discussions
#5
#5
If the problem is two or more parts that won't fit together correctly, make sure you check out both sides. Sometimes people jump to the conclusion that one of the two parts is the problem when actually the mating part is the problem. You also need to check any fasteners.

People often jump to the conclusion the mass produced part is not defective and focus on custom or low volume items. While a mass produced part is typically less likely to be the problem, mass produced parts can have defects.
 
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