Root Cause Anlysis
Root Cause Anlysis
Root Cause Anlysis
For Company
If this method followed every time, we assure
you will get the highest quality solution possible,
thus, improving the CCGs bottom-line
Should
Reality
GAP be
Target
Result
CHALLENGES CHALLENGES
6 Sigma
(Top Level Problems) Methodology
6 Sigma
(Top Level Problems) Methodology
PDCA, 8D
(Intermediate Problems) 7 QC Tools
Just Do it Actions
(Easy Problems)
• Deming was tasked with helping Japan rebuild its economy in the 1950’s.
DO
Modify Another Problem
Parameters or Improvement
CHECK
No Achieved
Goal?
Yes
ACT
Problem Statement:
1. Specify relevant details only
What? Specify which process or product has negative result or gap
Where? Location, place, part, department, section
When? time, day, month, year
Who? person responsible, client or customer
Why? is it important for the problem to be fixed
How? how it was detected?
How many? Quantifiable result, gap or measurement
1. Identification - Define the Problem
Problem Statement:
Example
What? Length of Cable
Where? Store
When? Today
Who? X&Y Project
Why? *
How? During material inspection
How many? 10 meter short
Problem Statement:
During material inspection today in store, the length of cable is 10
meter shorter than the required length for X & Y Project.
1. Identification - Define the Problem
The best thing to understand the problem is to GO to the affected place and
SEE it by yourself and collect FACTS what was really transpired.
1. Identification - Define the Problem
Flowcharting
1. Identification - Define the Problem
Process Mapping
MONOMER
START PREPARATION
PROGRAM GASKET
CB CASTING LENS WASHING LENS INSPECTION
PREPARATION PREPARATION
MOLDS
PREPARATION
END
1. Identification - Define the Problem
IS / IS NOT ANALYSIS
1. Identification - Define the Problem
Before proceeding
to next step:
Have we contained
the problem?
This require temporary
solution to protect or
isolate it to customer.
Steps of Problem Solving
1. Identification - Define the Problem
DESIRED
Rejection Rate
Evaluate
• Collect data to monitor performance
improvements.
• Make sure to follow the data collection plan
during the Pilot Stage.
• Communicate & feedback.
Validate
• Resolve any issues by finding
Countermeasures to ensure solution plan
continues. Concorde Corodex Group
7. Monitor / Evaluate Result
Tools:
Historical Data Analysis like Run Charts
Process Observation and Tracking
• If the result if not acceptable, stop the action and return to P-D-C
Phase until result became acceptable.
• Note:
> Make sure that all actions and result are properly documented.
> Don’t forget to congratulate your team for a job well done.
Why did
Why worn not know
belt to change
Why Belt
Why slipping
did not
charge
Why
Dead
Battery