RootCauseAnalysis

RootCauseAnalysis - Root Cause Analysis 1 Root Cause...

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1 Root Cause Analysis
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2 • Root Cause Analysis is a method that is used to address a problem or non-conformance, in order to get to the “root cause” of the problem. It is used so we can correct or eliminate the cause, and prevent the problem from recurring. • Traditional applications of Root Cause Analysis – Resolution of customer complaints and returns. – Disposition of non-conforming material (Scrap and Repair) via the Material Review process. – Corrective action plans resulting from internal and customer audits. Root Cause Analysis
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3 • Through this training course, you will: – Understand the meaning of “Root Cause” – Know the steps used to identify the root cause of problems. Objective
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4 What is Root Cause? Root Cause is the fundamental breakdown or failure of a process which, when resolved, prevents a recurrence of the problem. Or, in other words For a particular product problem, Root Cause is the factor that, when you fix it, the problem goes away and doesn’t come back. Root Cause Analysis is a systematic approach to get to the true root causes of our process problems.
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5 Philosophy of Root Cause Analysis • Each problem is an opportunity (“golden nugget”) because it can tell a story about why and how it occurred. • It is critical that everyone take a personal and active role in improving quality. • The “true” problem must be understood before action is taken. – Problems are often masked for a variety of reasons • To do this well, we must be – Both focused and open-minded – Both patient and quick – Above all, we must be relentless
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6 We Perform Root Cause Analysis to Prevent Turnbacks and Customer Escapes from Recurring Defects Own Next Later Before Found found at: Process Process Process Reaching By Step Step Step Customer Customer Cost: Impact: Very Minor Rework Significant Warranty Cost Minor Delay Rework Re- Admin. Cost schedule Delay in of Work Delivery Reputation Additional Loss of Inspection Market Share $1 $10 $100 $1,000 $10,000
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7 Symptom Approach vs. Root Cause Root Cause “Errors are the result of defects in the system. People are only part of the process.” “We need to find out why this is happening, and implement mistake- proofs so it won’t happen again.” “This is critical. We need to fix it for good, or it will come back and burn us.” If we do a poor job of identifying the root causes of our problems, we will waste time and resources putting bandaids on the symptoms of the problem. Symptom Approach “Errors are often a result of worker carelessness.” “We need to train and motivate workers to be more careful.” “We don’t have the time or resources to really get to the bottom of this problem.”
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8 How do we do Root Cause Analysis?
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RootCauseAnalysis - Root Cause Analysis 1 Root Cause...

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