Root Cause Analysis Archives - 6sigma https://6sigma.com/category/root-cause-analysis/ Six Sigma Certification and Training Tue, 23 Jan 2024 12:22:56 +0000 en-US hourly 1 https://6sigma.com/wp-content/uploads/2021/03/cropped-favicon-blue-68x68.png Root Cause Analysis Archives - 6sigma https://6sigma.com/category/root-cause-analysis/ 32 32 All about Effective Problem Statement https://6sigma.com/all-about-effective-problem-statement/ Mon, 03 Jan 2022 07:01:09 +0000 https://6sigma.com/?p=99231 Learning Six Sigma and achieving different belts is truly a daunting journey. But every journey begins with a problem or an aim. Writing a problem statement is just like that, you need to be elaborate, relevant, and completely address the issue you will be working on.

Let’s first understand the need and importance of […]

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Learning Six Sigma and achieving different belts is truly a daunting journey. But every journey begins with a problem or an aim. Writing a problem statement is just like that, you need to be elaborate, relevant, and completely address the issue you will be working on.

Let’s first understand the need and importance of having an effective problem statement. As the name suggests, a problem statement defines the gap that you want to address. It recognizes that there is a void between certain situations and current performances.

Before we go further, let us understand the roadmap for Six Sigma. The DMAIC model, one of the tools of Six Sigma methodology, enables you to improve the quality of results and the company’s processes. DMAIC stands for Define, Measure, Analyze, Improve, and Control, so whether you use this building block for project management or as a standalone quality improvement measure, the ‘Define Phase’ revolves around a concise yet detailed problem statement.

“[A user] needs [need] in order to accomplish [goal].” <define what it is>

With this basic formula, you can add information and arguments in favor of solving your problem.

Peter Peterka, a Six Sigma Master Black Belt, emphasizes the importance of facts and research within your problem statement. He focuses on, “Your problem statement can be very clear and simple, starting out as one or two sentences, but will be backed with data, research, and insights into the problem.”

The DMAIC Model 

Before going further, let’s understand the DMAIC model in Six Sigma. This will work as a map to address the issue, right down to improving and eliminating it. In turn, enabling you to understand the importance of having an effective problem statement, and how it affects the entire process.

  • Define phase

The purpose of the Define phase is to describe the problem and elaborate on how and how much it affects the organization or business. Define the customer, their issues with CTQ (Critical to Quality), and the core business process involved in the issue. 

Also talk about customers’ requirements, expectations, and reality. Discover the boundaries, what is feasible and what is not. This will help you map the process, for further improvements, and precisely map the process flow. 

  • Measure phase

The next phase is to measure the performance of the Core Business processes involved in the issue you’re addressing. This phase also includes the data collection plan, for this, you need to measure the performance of the Core Business Process involved. Develop a data collection plan for the process, collect relevant and up-to-date data from varied sources, then determine defects and metrics. This will help you understand the shortfall and present a clear picture of the problem.

  • Analyze phase

Then comes analyzing the data, following your process map to find out the root causes of defects and discover opportunities to improve performance. This phase also helps you to identify the gap between the current level of performance and Identify gaps between current performance and desired performance. This phase also enables you to prioritize opportunities, and also find sources of errors or variation.

  • Improve phase

The next phase deals with improving the target process. This is accomplished by designing creative solutions to fix the issue and also preventing problems that may arise due to it. This phase demands innovation and creativity, discipline, and leveraging technology to design, develop, and deploy the strategy or plan. 

  • Control phase

The job is not over yet as you have to take control of the implementations made by the Improve phase. You have to make sure that the new process runs smoothly, and does not revert to the ‘old way’. In this phase, you monitor the improvements and establish the system via modifying systems, structures, etc. Also, developing documentation, guidelines, etc. to make sure that the control remains and the process does not ward off its desired route.

How to start writing an effective problem statement?

When writing a problem statement, one of the best strategies to use is 5W2H (What? Why? Where? When? Who? How? How Much?). This method allows you to ask the right questions, in cascading order, leading you to create a foolproof problem statement.

The 5W2H tool establishes a clear and direct guideline for addressing a problem or a process. This tool gives the writer a clear set of rules to adhere to while making a problem statement effective. This tool enables you to have a guided route to tackling the problem, and provide a crisp explanation of the problem you’re addressing.

Also, before starting to write your problem, find all the relevant data about it. This will make it easier for you to understand the trend, and spot a pattern if there is any. The next thing to keep in mind is readability and presentation.

As it is said, your first impression might be your last. Let the problem sink in first, don’t jump onto writing it down. It’s always recommended to keep pointers, which will guide you to write effectively, addressing all the issues in a simplified and organized manner.

Tools & Techniques to use when writing an effective problem statement?

Every team develops its own processes to create effective problem statements. The process is very flexible. You can arrange it according to your liking and your business methodology. But there’s one methodology that stands out the most — The 5 Whys.

What are the 5 whys?

The 5 Whys is one of the most effective techniques for Root Cause Analysis (learn more about RCA in our previous blog). Every team which faces hurdles in their task can utilize the 5 Whys approach to find the root cause of any problem and protect the process from recurring mistakes and failures.

How to Complete a Five Whys Root Cause Analysis?

  1. Begin with a specific problem. Find the issue you are facing. This will resolve your team to pinpoint the common root cause problem.
  2. Ask why the problem happened and write the solution down to the specific problem you listed.
  3. Keep asking WHY? to each of the succeeding problems and to its answers until you reach the root cause of the problem.
  4. Make sure the team manages to resolve all the Whys? To the problems and their solutions. This may take some time due to the detailed filtration of the entire flow.

The Five Whys Tools

The easiest approach to conduct the 5 Whys is to simply write down on a piece of paper. However, for a bigger project, you may require something more than a piece of paper. The Fishbone or the Ishikawa diagram can help during the initial process of identifying the problems. Learn more about the Ishikawa diagram in one of our many Six Sigma-related blogs. Gather all of the root-cause relationships and assess which of them had a greater impact on the original problem.

Few more important points to consider:

  • You have to make sure that your statement addresses one issue. Yes, you can write multiple issues, but make it easier for the reader, and break them into different statements. As you delve deeper into the problem, you’ll find many links to other problematic areas. But the whole point is to focus on one issue, then move on to the next. Because Rome wasn’t built in a day!
  • As you find other problems in the underlying areas of your core issues, you should avoid blaming any particular team/process. Blaming someone else is equivalent to giving up on the problem yourself. This would also make you look like you’re being overwhelmed and narrow-minded about finding root causes, etc.
  • The most important point to note is to make sure that you don’t address any solutions to the gap you’re stating. As the problem statement just urges the management to take urgent actions, the problem might be even bigger or something else entirely.

The problem statement just states facts, trends, patterns, data, etc. about the underlying cause, it is a message to push management for further action and investigation. So, make sure you keep it to that and check all the boxes.

What makes a problem statement effective?

We often wonder, why does it need to be effective when it’s going to solve a major issue and benefit the organization anyway?

Well, addressing your issue to the management is not your sole purpose. You need to make it clear for every person involved in the process. The golden rule to follow is if an unbiased individual can clearly understand and get your problem statement. It is effective!

The Define phase of DMAIC takes extra precedence over other phases. Because not everyone looks at or understands the problem in the same way you do. The best you can do to get everyone on the same page is to create a lucid and descriptive statement. That talks to the point, covering all open-ended threads, which can raise conflicts or questions.

Now we have understood the need and importance of a problem statement. Let’s focus on the next part which curtails around making your problem statement effective. 

An effective problem statement should include:

  • A clear understanding of the process issues
  • The improvement goals
  • The actions that are going to be taken for change

To include all this, you can:

  • Have a thorough conversation with your top management, ask for inputs, and other possible revenue leaks or overhead costs. 
  • You can map level Y (which is the Key Business Outcome). Y will often be referred to in the Six Sigma DMAIC approach and it is called KPOV (Key Process Output variable).
  • One thing to keep in mind is drafting a SMART problem statement. SMART stands for Smart, Measurable, Actual, and Time-Bound. This will all be clarified in the examples given in the next and give you an idea about how to write an effective problem statement.

To get a deeper understanding and get into the writing part of the Define phase, Project Charter becomes a useful tool. Consider it as a pitch, which includes all the information, and enables you to create an effective problem statement. 

A Project Charter includes:

  • Background and Purpose: a crisp and clear description of the issue, how it is affecting the business along, its importance, issues with the current process, reasons stated for the project.
  • Mission Statement: A concise statement of the purpose of the project and goals expected to achieve as well as the direction of action planned.
  • Scope: This should include but not limited to:
  1.  Boundaries & limitations
  2. Expect Project goals
  3. Timeline of steps
  4. Deliverables of the said project when completed
  5. Detailed cost estimates of project
  6. Organizational interfaces, departments, or groups affected by said project
  7. The urgency of the project
  • Team Involved and Roles: List of members and areas of expertise, including external stakeholders, everyone on the project, and teams that should be included.
  • Operational Framework: This should include locations, accountability, the decision-making process that is protocol, and what methods are to be used for conflict resolution.
  • Performance Measures: Measure for team performance, deadlines, process efficiency measures, outcome measures, or goals achieved for the project.
  • Support Requirements: Any outside support needed such as consultants, outside systems, or even vendors 

Using the Project Charter enables you to achieve a clear, detailed, and effective problem statement. This also allows you to clearly state the Define phase, and create a problem statement that is lucid yet exhaustive in its context and depth.

Examples

The organization has been producing a lot of defective items.

The statement above does not provide readers with any information about the organization. It just states a major problem with no particular process in vision. Also, it does not talk about the cost incurred by the organization. The gravity of the situation and if any urgent measures are required. And what about Customer Satisfaction?

As long as a problem does not benefit the customers, why would an organization make these changes?

Now let us take the same statement, and turn it into an effective problem statement.

In Ex Machines Ltd., the rate of defective products (remote sets for TVs) has increased by 45% over the past 5 months. The loss resulting due to the defective products is $25,000 combined over the past 5 months. This is affecting the supply chain, and also tarnishing the company’s reputation with the customers.  

This statement tells the problem and is also concise, talks about the duration, and also the revenue in numbers (avoid approximated figures and random figures). The management can get a clear and defined problem, understand its urgency, and what benefits come from it. If there is a customer experience or satisfaction added, make sure you mention it. With this, you can also see how 5W2H works, along with SMART.

  • Let’s take another example

The hospital is losing money on beds, due to delayed time in response and other aspects.

What this statement should be like: 

In ABC hospitals, there are fewer beds and poor bed management for patients. Measured over the past 8 months, year to year, the loss incurred and insurance premiums due to casualties is $500,000. This has impacted the hospital’s credentials and ramped up the insurance premiums. 

Conclusion 

This is all there is to know about writing an effective problem statement. You should always keep in mind that every solution begins with a problem, and your solution is as good as the problem you state. 

An effective problem statement will take your project a long way ahead, and give your project the desired level of attention and importance.

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Root Cause Analysis with the 5 Whys https://6sigma.com/root-cause-analysis-with-the-5-whys/ https://6sigma.com/root-cause-analysis-with-the-5-whys/#respond Mon, 01 Mar 2021 18:37:39 +0000 https://6sigma.com/?p=27600 5 whys

Sometimes, problems can be stubborn and refuse to completely disappear despite trying different things. They just keep coming back in one way or the other. It is at this point that it is important to understand that the reason the […]

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5 whys

Sometimes, problems can be stubborn and refuse to completely disappear despite trying different things. They just keep coming back in one way or the other. It is at this point that it is important to understand that the reason the problem keeps happening, again and again, is because the underlying issue isn’t resolved. 

That is the problem with employing quick fixes instead of long-term solutions – you only fix the problem on a superficial level (mask the symptoms). Worse still, those resources wasted on the quick fix could have been used in identifying and eliminating the root cause of the problem. To prevent this from happening, Six Sigma has root cause analysis (RCA).

RCA brings several tools that teams can use to get rid of a problem indefinitely. One of the most popular tools is known as the 5 Whys. It involves looking at the problem and asking “Why?” five times until the root cause is identified.

In this post, we are going to outline how organizations can implement this tool.

Implementing the 5 Whys

A big part of successful implementing 5 Whys is understanding the issue and then making changes to eliminate it once and for all. Many teams who have used the tool have been surprised to find that the cause of the problem is something they didn’t expect. This speaks to the true power of the 5 Whys since underlying causes are not always obvious.

Here are the steps to implement it:

Put Together a Team

When assembling the team, make sure it has people who have been directly affected by the problem. If not, make sure they at least noticed it. A team leader should be selected who will be in charge of the meetings and delegating responsibilities to team members.

Define the Problem

Since the problem has already been identified, the team should focus on coming up with a problem statement. It should be clear, concise and agreed upon by everyone in the team.

Ask Why 5 Times

Here, the team leader should start asking “Why?” and team members should contribute. Their contributions should be fact-based and data-backed. Keep in mind that it is not a hard rule to ask why five times. The team leader can ask it until the root cause is identified, even if it is less or more than five times.

Make Changes

With the root cause identified, the team then moves on to suggest, agree on and implement effective changes that will make the problem go away and never happen again.

Monitor Changes

The changes need to be monitored to ensure they have effectively eliminated the problem. If not, improvements need to be made – they can also be replaced. The team shouldn’t be afraid to go back to the drawing board and ask “Why?” again in case they identified the wrong underlying cause.

Conclusion

When facing a problem that refuses to go away, Six Sigma can help. Specifically, it can help organizations identify the root cause of the problem using tools like the 5 Whys. Only by getting rid of the underlying cause can you rest assured the problem has been dealt with and will not be a recurrent issue.

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Effective Problem Solving Through Lean Tools https://6sigma.com/effective-problem-solving-through-lean-tools/ https://6sigma.com/effective-problem-solving-through-lean-tools/#respond Mon, 22 Feb 2021 20:54:37 +0000 https://6sigma.com/?p=27577 When a problem or issue surfaces in quality management the set of tools and techniques used to get to the bottom of it are essentially part of Root Cause Analysis (RCA). Although some people prefer to take a freestyle approach to problem-solving, RCA’s tools make the whole endeavour more structured and methodical. This […]

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lean tools

When a problem or issue surfaces in quality management the set of tools and techniques used to get to the bottom of it are essentially part of Root Cause Analysis (RCA). Although some people prefer to take a freestyle approach to problem-solving, RCA’s tools make the whole endeavour more structured and methodical. This has been shown to lead to excellent results.

Some of the tools allow you to look past what is obvious to uncover the underlying cause. Others allow you to visualize the problem so you can look at it from a different perspective. And each tool is designed to help you see the real, hidden issue, which will prevent the problem or issue from ever happening again once fixed.

This saves the team a lot of time. Constantly working on surface problems is nothing more than patchwork. If the main cause isn’t fixed, the problem becomes recurring – sometimes it gets worse with each reoccurrence. Furthermore, it prevents the team from focusing on the wrong cause or something that doesn’t need to be fixed at all.

When it comes to RCA, there are many tools that teams can use. Here are the most common ones.

Fishbone Diagram

When the problem being faced is complex in nature, the fishbone diagram is used. It allows the team to categorize possible causes into homogeneous groups and sub-groups. It is especially handy to use in the event the root cause is hidden under various surface problems. Another name for the diagram is the cause-and-effect diagram.

5 Whys

The 5 Whys puts you in the shoes of a detective trying to uncover the root cause of a problem. There’s nothing complicated about it either since all you have to do is ask the question “Why?” five times – as a rule of thumb, not a hard rule – until the underlying cause is revealed. It works best on rudimentary issues, so it might not be the best option if there is a need for quantitative analysis.

Pareto Chart

Causes are 20% responsible for the effects seen 80% of the time. This is the underlying principle behind the Pareto Chart. This visualization tool provides a snapshot of common errors so they can be seen from a glance. It shows their causes in descending order, helping you tackle them in order of relevance and urgency.

Failure Mode and Effect Analysis (FMEA)

When a system encounters a particular failure, the FMEA is the best tool to use to shed light on it. The Failure Mode component of the tool is about brainstorming potential things that can lead to system failure. These are the failure modes. Effects Analysis dives deeper into the effects of each of the failure modes identified in the previous step.

Conclusion

Taking Root Cause Analysis seriously is just one of the many ways organizations achieve Six Sigma. There’s no one way to carry out RCA since every problem is unique to the organization. While other tools can be used to conduct RCA as well, these are ones that successful organizations use from time to time. Each one has proved time and time again to be effective and getting rid of problems and issues once and for all.

 

 

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Follow These Steps to Conduct a Root Cause Analysis https://6sigma.com/follow-these-steps-to-conduct-a-root-cause-analysis/ https://6sigma.com/follow-these-steps-to-conduct-a-root-cause-analysis/#respond Tue, 19 Jan 2021 12:31:45 +0000 https://6sigma.com/?p=27539 When coming up with a standardized approach to continuous process improvement, root cause analysis is a critical component. It seeks to identify the problem, its source and then fix it once and for all so it never pops up again. Ultimately, this improves the quality of the process’s outputs. When it comes to […]

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root cause analysis

When coming up with a standardized approach to continuous process improvement, root cause analysis is a critical component. It seeks to identify the problem, its source and then fix it once and for all so it never pops up again. Ultimately, this improves the quality of the process’s outputs. When it comes to root cause analysis, time is of the essence. Action needs to be taken the moment the problem is identified before it becomes a really big and costly issue. 

While there is no one way to conduct a root cause analysis, here are seven steps that you can follow to ensure that it is done properly:

1. Identify and Sort the Problems

All businesses experience issues in one form or the other, but what matters is how they are handled. To begin with, it is essential to identify the problems and then sort them in order of severity so the most urgent ones can be tackled first.

2. Define the Problem

For the problem chosen to be solved first, it needs to be clearly and concisely defined, with emphasis on its solvability. There’s no point trying to tackle problems that have no discernible solution at the moment.

3. Identify Possible Causes

A team should be gathered for a brainstorming session. This is where the team can utilize one of Six Sigma’s strategies for root cause analysis: the five whys. The strategy involves asking the question “Why?” five times in order to get to the underlying causes of the problem. Five is not a hard rule but a rule of thumb – the question can be asked as little or as many times as needed.

Then the team will discuss and select the possible ways to fix the problem. It is important to always pay attention to the root causes in order to come up with an effective solution.

4. Make Improvements

At this stage all the improvements should be implemented and communicated to everyone involved – don’t leave anyone out. Clearly communicating things like the deadlines, deliverables, reasons and benefits can go a long way towards making continuous improvement stick.

5. Review the Improvements

Review the improvements that were made and make amendments where necessary. If the problem persists, don’t be afraid to go back to step number 3.

6. Standardize the Procedures

Create documents that outline what procedures need to be standardized and be sure to share them with everyone involved. Also, ask yourselves if these procedures are applicable elsewhere in the organization (HR? Customer service? Marketing?).

7. Review and Control the New Procedures

Check on a regular basis to ensure that the standardized procedures are effectively rectifying the problem. Also, make sure that people in the organization are following them by reviewing the procedures every 3-6 months.

Conclusion

Conducting root cause analysis is not an extremely complicated process. However, if done properly, it can produce benefits that can make the organization competitive and profitable. There is no one way to conduct, but the above-mentioned seven steps can help you do it if they are in line with the way your organization operates. Otherwise, they can be adjusted to suit your organization.

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The Importance of Root Cause Analysis During Incident Investigation https://6sigma.com/the-importance-of-root-cause-analysis-during-incident-investigation/ https://6sigma.com/the-importance-of-root-cause-analysis-during-incident-investigation/#respond Tue, 20 Oct 2020 18:24:51 +0000 https://6sigma.com/?p=27396 It is highly unlikely that an organization, whether it is in manufacturing, hospitality, or health care, can run without incident. However, the way the incidents are handled is what can help the organization remain competitive […]

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It is highly unlikely that an organization, whether it is in manufacturing, hospitality, or health care, can run without incident. However, the way the incidents are handled is what can help the organization remain competitive and achieve its business goals. When an incident happens, it needs to be investigated and effectively eliminated, which is where root cause analysis (RCA) comes into the picture.

There are many reasons why organizations should take Root Cause Analysis seriously. Organizations have used it for decades as part of their continuous improvement arsenal. But before we discuss how important RCA is when investigating an incident, let us quickly define what it is.

What is Root Cause Analysis and Why is it Important During Incident Investigation?

Root cause analysis can essentially be defined as a methodology that helps analyze an incident in order to identify the underlying (root) cause. Once the underlying cause has been identified, corrective steps are taken to eliminate it. So RCA is not just patchwork that takes care of incidents on a surface level. 

When RCA is done properly, it means there is an extremely low (almost negligible) chance of the incident reoccurring in the future. This is perhaps one of the biggest reasons why RCA is important during an incident investigation.

Other Reasons Root Cause Analysis is Important

Besides helping an organization find a permanent solution for an incident, here are other reasons why organizations should conduct root cause analysis:

Helps Solve Similar Incidents

One of the end results of a root cause analysis is that an organization will come up with a systematic and logical approach to handling incidents. This approach can be adopted to help prevent similar incidents from occurring or reoccurring. That way, the workplace becomes a safer and more productive environment.

Products Get to Market Faster

When incidents occur, they slow down or completely stop production. While the incident is still in effect, it means that the organization’s ability to get products to market is significantly reduced. With the incident permanently dealt with, current and future delays are no longer an issue, which means products get to market faster and the organization makes money faster as well.

Reduces Costs

Defects are costly to rectify, especially when they occur in the later stages of the process. When defects are not caught and rectified, the defective products can make their way into the hands of customers. And since no one likes buying a defective product, it means these customers will be unwilling to buy from the organization again.

Improves Safety and Reliability

RCA makes products safer and more reliable. This means that consumers will have increased trust in the organization’s products. Moreover, with no incidents to worry about, current employees will feel much safer and highly-skilled workers will want to work for the organization.

Conclusion

As you can see, root cause analysis helps prevent incidents from reoccurring in the future by identifying and eliminating the underlying cause. Furthermore, it helps prevent similar problems from reoccurring, helps get products to market faster, reduces costs and increases the safety and reliability of products. Any organization that wants to stay ahead of the competition while being profitable will take RCA seriously.

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Root Cause Analysis Training Is the Mother of All Training https://6sigma.com/root-cause-analysis-training-is-the-mother-of-all-training/ https://6sigma.com/root-cause-analysis-training-is-the-mother-of-all-training/#respond Mon, 28 Sep 2020 23:11:57 +0000 https://6sigma.com/?p=27345 Think about it — to have a training system that is a template for finding the cause of an issue or problem in any industry or any organization is simply genius. Root cause analysis training should be taught in all schools! 

Mistakes or causes for mistakes is a universal problem; unfortunately […]

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Think about it — to have a training system that is a template for finding the cause of an issue or problem in any industry or any organization is simply genius. Root cause analysis training should be taught in all schools! 

Mistakes or causes for mistakes is a universal problem; unfortunately when we as humans are confronted with a recurring problem or issue, it is because we are usually in the middle of the time crunch of the daily processes. The first thing we usually do is to put a bandaid on the issue so we can hurry up and finish. This action gets us through the day, which of course is the reason the problem is recurring. We might think we know why this problem is happening and recurring but you really don’t know. The problem might show up when you noticed it, but like the name states, it’s the root cause of that problem that you are after, and like it implies it will take some digging.

In our Root Cause Analysis training, you will:

  • Know what to do when problems occur
  • Define, validate and decide if the problem should be solved
  • Use a team approach and understand team dynamics
  • Take appropriate interim actions
  • Choose the most appropriate Root Cause Analysis methods for the situation
  • Determine and implement the best sustainable solution

Topics covered:

  • What Root Cause Analysis (RCA) is, why we need it and when to use it
  • Problem-Solving Process Flowchart (8D Roadmap)
  • Problems vs. Opportunities
  • Preventative Practices
  • Problem Detection & Specification
  • Problem Anatomy = |Should – Actual|*Risk
  • Causes to Determine
  • Cause Structures
  • Situation Appraisal
  • Known vs. Unknown Cause
  • Using Facts, Evidence & Assumptions
  • Interim Actions
  • Using a Team Approach
  • Risk Analysis Tools
  • Importance of Language
  • Cause-Effect Mapping Methods
  • Potential Cause Filters and Generators
  • Human Error
  • Choosing the Best Solution Profile
  • Solution Validation
  • Exercises & Case Studies

Once you know how it is done, you can apply this to anything you are having a recurring problem with, and wish to get to the bottom of what is actually causing the problem.

This is a live virtual class with an actual instructor you can interact with to answer your questions. This is a 3-day event — please go to our website to register for your preferred dates. For more information on this or our other Lean Six Sigma courses or services, please visit 6sigma.com

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Root Cause Analysis: Get to the Root of the Problem https://6sigma.com/root-cause-analysis-get-to-the-root-of-the-problem/ https://6sigma.com/root-cause-analysis-get-to-the-root-of-the-problem/#respond Mon, 29 Jul 2019 17:13:52 +0000 https://6sigma.com/?p=23418 Why get to the root of your business problem? The primary reason is so you can, once and for all, get rid of the problem. As long as the root of the problem exists, you will have the same problem over and over again. So the solution is simple: conduct a root […]

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Why get to the root of your business problem? The primary reason is so you can, once and for all, get rid of the problem. As long as the root of the problem exists, you will have the same problem over and over again. So the solution is simple: conduct a root cause analysis (RCA). Follow this simple template outlined below and you will figure out the root cause and develop solutions to be rid of your issue once and for all. This is a Six Sigma great tool.

root cause analysis tool infographic

 

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Tools Used in Root Cause Analysis https://6sigma.com/tools-used-in-root-cause-analysis/ https://6sigma.com/tools-used-in-root-cause-analysis/#respond Mon, 18 Feb 2019 15:55:57 +0000 https://6sigma.com/?p=22984 Finding the root cause of an issue could eliminate the problem completely, and in doing so can improve the quality of your product or service. Constantly monitoring your work processes and data is the secret, and luckily there are tools that one can use to make this easier. This is where root cause analysis […]

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Finding the root cause of an issue could eliminate the problem completely, and in doing so can improve the quality of your product or service. Constantly monitoring your work processes and data is the secret, and luckily there are tools that one can use to make this easier. This is where root cause analysis comes in. 

Here are several effective tools to monitor your work process and help locate the root cause of a problem:

Brainstorming and Fishbone Diagrams: These two are separate tools, but even more powerful when used in succession. 

  • Brainstorming: Here you would bring in your team or those you’ve chosen for this task, inform them of the issue at hand, and designate someone who will write down possible reasons and solutions that are brought up. Everyone involved is given the opportunity and participates. 
  • Fishbone Diagrams: This is also referred to as a cause and effect diagram, and it is a great way to identify the root causes of an issue and sort them out into categories. After your brainstorming session, you can put the possible solutions in with the appropriate category on the diagram. You will be able to sort out and keep only the strong possibilities.

The 5 Whys: Another simple tool that is powerful in its results. Just keep asking why; don’t worry, the answer will change as you keep progressing. Eventually, you will have the answer in front of you. This uses our own capabilities as a resource. It is genius in its concept and so simple to use.

Process Flow Charts: This is a visual of your entire work process. It lets you visualize the steps of your work process and what it consists of. You can even see what would change the outcome and at what point. The Process Flow Chart allows you to understand how a process works, which helps everyone stay on the same page when discussing a possible restructuring of a work process.

Interested in learning more about Root Cause Analysis? Learn more about our RCA classes!

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Root Cause Analysis (RCA): Use Once and For All https://6sigma.com/root-cause-analysis-rca-use-once-and-for-all/ https://6sigma.com/root-cause-analysis-rca-use-once-and-for-all/#respond Mon, 29 Oct 2018 15:35:33 +0000 https://6sigma.com/?p=22693 Root Cause Analysis (RCA) is to one of the most important tools for getting rid of an issue once and for all. Yet, most people don’t get to the root cause of the issue, since most problems are recurring ones. You could say that a recurring problem remains this way because fixing it to the […]

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Root Cause Analysis (RCA) is to one of the most important tools for getting rid of an issue once and for all. Yet, most people don’t get to the root cause of the issue, since most problems are recurring ones. You could say that a recurring problem remains this way because fixing it to the point that it needs to be fixed never occurs. If the problem had been corrected, cut out by its roots, and monitored, it’s existence would have been terminated.

Check out this breakdown of Root Cause Analysis (RCA) in our infographic.

root cause analysis infographic

For more information on our Lean Six Sigma training courses and services, please visit our class schedule!


Read more on Root Cause Analysis (RCA):

Root Cause Analysis with the 5 Whys

The Importance of Root Cause Analysis During Incident Investigation

Root Cause Analysis Training Is the Mother of All Training

Lean Six Sigma Root Cause Analysis Tools For Spring Cleaning

Root Cause Analysis Can Save Your Business

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INFOGRAPHIC: The 5 Whys and the Root Cause https://6sigma.com/infographic-the-5-whys-and-the-root-cause/ https://6sigma.com/infographic-the-5-whys-and-the-root-cause/#respond Mon, 06 Aug 2018 13:00:25 +0000 https://6sigma.com/?p=22402 The 5 Whys is the best Six Sigma tool to find out the root cause of a problem. It is to be used during the Analyze Phase of the DMAIC process. The steps are simple — just write down the specific issue or problem. Then ask why the problem happens and answer the question. Keep asking […]

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The 5 Whys is the best Six Sigma tool to find out the root cause of a problem. It is to be used during the Analyze Phase of the DMAIC process. The steps are simple — just write down the specific issue or problem. Then ask why the problem happens and answer the question. Keep asking until you are satisfied with your answer. This is a great way to really get down to the root of the problem. Sometimes it takes more than 5 Whys to get your true answer! The infographic below outlines a example of this process.

5 whys 6 sigma infographic

 

 

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Lean Six Sigma Root Cause Analysis Tools For Spring Cleaning https://6sigma.com/lean-six-sigma-root-cause-analysis-tools-spring-cleaning/ https://6sigma.com/lean-six-sigma-root-cause-analysis-tools-spring-cleaning/#respond Mon, 05 Mar 2018 23:21:02 +0000 https://6sigma.com/?p=21907 Many of the Lean Six Sigma tools have easy home use application. We see this, for example, in the Lean Six Sigma 5S tool for organization — it applies perfectly for spring cleaning of the home or parts of the home. How about we use the most frequently used root cause analysis (RCA) tools to […]

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Many of the Lean Six Sigma tools have easy home use application. We see this, for example, in the Lean Six Sigma 5S tool for organization — it applies perfectly for spring cleaning of the home or parts of the home. How about we use the most frequently used root cause analysis (RCA) tools to play the “blame game” when figuring out what is causing the disarray at home?

root cause analysis

The reason that conducting a root cause analysis is so important is that it is the only way you can identify exactly what is the root cause of the problem. This will result in the best possible solution that will be both effective and efficient.

The Best RCA Tools to Play the Blame Game

  1. The 5 Whys: This Lean Six Sigma tool is so easy that kids already play it. Just keep asking why until a meaningful conclusion has been established. Many times it could take as long as it has taken to answer one of your kid’s most challenging questions.
  2. Flowcharts: Everyone can visually see what is being impacted with flowcharts; these make things clear to kids as well. Make sure you keep the flowcharts simple.
  3. Fishbone Diagram: This is also known as the cause and effect diagram. Used in conjunction with the 5 Whys when the 5 Whys are too general. The Fishbone diagram will put causes into specific categories, indicating how that cause impacts the outcome.
  4. Brainstorming: This will bring the entire family together so everyone can have their say or input. Everyone’s input counts and is added, so this is a great Lean Six Sigma tool for family participation. The result in the brainstorming session should identify the root cause of the problem (why the garage always gets messy) and try to come up with possible solutions.
  5. Affinity Diagram: This can be used with the information gathered from the brainstorming session, by organizing and possibly consolidating that information to further relate to the issue at hand.

This is yet another creative way to use the magic of Six Sigma and Lean Six Sigma tools in our daily lives to deal with common, everyday organization issues.

Interested in learning more about root cause analysis? Learn about our RCA training!

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Root Cause Analysis: Because Nothing is Perfect https://6sigma.com/root-cause-analysis-nothing-perfect/ https://6sigma.com/root-cause-analysis-nothing-perfect/#respond Mon, 22 Jan 2018 23:22:14 +0000 https://6sigma.com/?p=21801 Imagine having the knowledge of how to identify the root cause of any issue that could come up. This priceless knowledge is what we are offering in our exclusive root cause analysis training.

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Imagine having the knowledge of how to identify the root cause of any issue that could come up. This priceless knowledge is what we are offering in our exclusive root cause analysis training.

root cause analysis training

Why Is Root Cause Analysis so Important?

Root cause analysis can single-handedly eliminate an issue; and by eliminating the issue your business will run more efficiently. You’ll be able to give more focus to your customer base, because the issue that was causing issues for your business is gone.

A Simple Basic Step-by-Step Root Cause Analysis (RCA)

  • Define the Problem: Be specific and as detailed as possible.
  • Understand the Problem: Use actual data having to do with the problem. Make sure you have a clear understanding of the problem; this will ensure the correct root cause will be found and eliminated.
  • Immediate Action: The most obvious issue is usually located close to the “effect.”
  • Corrective Action: Identify the most likely underlying causes of the problem, and prioritize action taken from that point.
  • Confirm the Solution: After you’ve done all the preliminaries and have implemented the solution, make sure you confirm the success of the solution.

This would ensure that the new rules and methods would be established, thus avoiding the same problem from recurring.

So, What Tools Are Needed in Conducting a Root Cause Analysis?

Fishbone (Ishikawa) Diagram: This can help identify causes of the issue

Pareto Chart: This is a bar graph that visually shows significance of the elements involved.

Scatter Diagram: This graphs numerical data to help look for a common link.

5 Whys: This is by far the most creative and a very simple tool to use. You state your problem and start asking why until you get to the root cause. The simplicity is what makes this a genius tool.

We offer root cause analysis training in several cities. It is the most comprehensive course to date. Among many topics, you will learn:

  • The Problem-Solving Process Flowchart (8D Roadmap)
  • Flowcharts
  • Problem vs. Opportunities
  • Cause & Effect Mapping Methods
  • Using Facts, Evidence, and Assumptions

For more information about our root cause analysis coursework, please visit 6sigma.com.

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Telling the Difference: Six Sigma, Lean, or Kaizen https://6sigma.com/21516-2/ https://6sigma.com/21516-2/#respond Mon, 14 Aug 2017 21:57:34 +0000 https://6sigma.com/?p=21516 Not sure of the project you’re working on? Uncertain what separates waste from variation? Don’t know your process improvement from your continuous improvement? Lean Six Sigma practitioners need to know the difference between each of these three methodologies. While they each share similarities, they all work in different ways, and toward different goals. As […]

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Not sure of the project you’re working on? Uncertain what separates waste from variation? Don’t know your process improvement from your continuous improvement? Lean Six Sigma practitioners need to know the difference between each of these three methodologies. While they each share similarities, they all work in different ways, and toward different goals. As such, it’s essential, and highly advantageous, to understand their individual philosophies. Today, we ask the all-important question about Six Sigma, Lean, and Kaizen: which is which?

Six Sigma

Six Sigma is the world’s most trusted process improvement methodology. But what does it entail? Six Sigma’s primary aim is to reduce variation, to create greater quality and efficiency in the workplace. Like any science, Six Sigma uses statistics to validate hypotheses, with practitioners using data to justify their decisions and predict future problems. Furthermore, your mastery of Six Sigma depends on belt color, as different belts require different levels of training. Yellow Belts, for instance, have a basic understanding of Six Sigma and can conduct simple data analysis. Master Black Belts, on the other hand, are just that – masters of Six Sigma knowledge and technique. They utilize tools like DMAIC, hypothesis testing, statistical process control, root cause analysis, and Pareto charts. With these key skills, practitioners make lasting process and quality improvements in industries like manufacturing.

Lean

Lean shares many similarities with both Six Sigma, each complementing the other, giving rise to a hybrid methodology: Lean Six Sigma. LSS combines the best qualities of both improvement approaches to create even greater efficiency. But Lean alone takes a different approach. In Lean terms, anything that does not add value is a threat to production. Utilizing in-depth analytical techniques to identify waste, Lean allows you to eliminate it at the source. Below are the eight types of waste (Muda) that occur in the workplace.

  1. Transport. Movement of people, products or information to different locations.
  2. Inventory. Unnecessary storage of parts, pieces or documentation.
  3. Motion. Any extraneous human motion or action. E.g. bending down, turning around, reaching, lifting, or walking.
  4. Waiting. Needless waiting for parts, instructions, information or equipment.
  5. Overproduction. Producing more product than your current demand due to human error. g. producing fifty batches of mobile phones when the customer only wanted ten.
  6. Over-processing. Maintaining overly strict procedures or excessively high-grade materials than you need.
  7. Defect. Variation, defective products, reworking, repeating tasks, incorrect documentation.
  8. Skills. Failure to utilize talented employees appropriately. Delegating tasks to those unqualified to perform them.

Kaizen

Kaizen is a Japanese word, also known as continuous improvement, though its literal meaning is “good change.” As such, any positive change to a business’s production processes, quality, efficiency or productivity is Kaizen. There is some overlap with both Lean and Six Sigma, but, the difference between them is that Kaizen is not a practice. Kaizen is a culture, an attitude towards work, that you must cultivate to see positive change. You can use Lean and Six Sigma to build a continuous improvement culture at work. Moreover, the key is in the word “continuous,” in that there is no end. Therefore, Kaizen is not a single practice but a way of thinking. The aim of which is to create a sustained and continuous effort to maximize your business’s productivity and efficiency.

Learn more about our training and Courses

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5 Whys: A Six Sigma Tool So Simple, a Toddler Could Have Invented It https://6sigma.com/5-whys-six-sigma-tool-simple-toddler-invented/ https://6sigma.com/5-whys-six-sigma-tool-simple-toddler-invented/#respond Mon, 07 Aug 2017 01:57:23 +0000 https://6sigma.com/?p=21476 Finding the root cause of a problem is the only way to get rid of the problem. Many times, it takes awhile to actually find out what is causing the issue, but the time spent is well worth it. Six Sigma has a simple yet brilliant tool that could very well have been created by […]

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Finding the root cause of a problem is the only way to get rid of the problem. Many times, it takes awhile to actually find out what is causing the issue, but the time spent is well worth it. Six Sigma has a simple yet brilliant tool that could very well have been created by a toddler. The tool is called the 5 Whys…and spoiler alert — it could take more than 5 Whys!

5 whys six sigma tool

Very much like a child would ask their parent the endless “why,” that is how this tool is used.

How to Use the 5 Whys

State what the problem is in writing. Be specific and as detailed as necessary. Visually seeing the problem helps the team focus on the exact issue.

Now ask the first why. When you get an answer, place this underneath the problem.

If the first answer doesn’t get to the root of the problem, go back and ask “why” again.

Keep asking “why” until the answer that is given gets to the root cause of the problem. You’ll know when you find the exact cause of the issue.

The 5 Whys is a filtering system of sorts. Each time you ask “why” it brings you closer to the root of the problem, by filtering out the small inconveniences that are layered at the top, covering a much deeper cause for malaise.

Another benefit of using the 5 Whys Six Sigma tool is that it helps determine other different root causes that manifest within the same basic problem. So by tackling the different root causes, you’ll be able to see how that changes the dynamic of the problem.

*Remember every time you ask why, you’re asking why to the deeper new answer, and not to the original first answer.

For more information on our Six Sigma courses or services please 6sigma.com. Be sure to check out our fall schedule!

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Root Cause Analysis Can Save Your Business https://6sigma.com/root-cause-analysis-can-save-business/ https://6sigma.com/root-cause-analysis-can-save-business/#respond Sun, 30 Apr 2017 23:54:32 +0000 https://6sigma.com/?p=21051 Root Cause Analysis (RCA) is a term used to describe the process of using specific tools and methods and approaches to expose the true causes of problems or recurring issues.

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Root Cause Analysis (RCA) is a term used to describe the process of using specific tools and methods and approaches to expose the true causes of problems or recurring issues.

root cause analysis

The main reason this collective term is so important is because without figuring out what the root of the problem is, the problem will re-occur. The goal is to eradicate the problem permanently.

The Five-Step RCA DMAIC Process:

  • Step 1: Define the problem
  • Step 2: Measure and collect data to determine the severity of the problem
  • Step 3: Analyze to determine the root cause of the problem
  • Step 4: Improve with a solution to solve the problem
  • Step 5: Control determine how you will sustain the improved process

A great tool for identifying the root cause of a problem is the 5 Whys. Here is a breakdown of this important tool:

  • State the problem
  • Determine the cause by asking “why” until the cause has been established
  • Use a Cause & Effect chart to establish the relationship between the two
  • Use a Pareto Chart to show the significance of the identified root causes

The entire process is detailed and must be first broken down into specific pieces to be dealt with. An important detail to remember is that you are dealing with the actual problem and not just the symptom.

The simplicity of the 5 Whys tool will make discovering the root cause easy to determine. The Pareto chart and the Cause and Effect chart will show you the significance of the stated issue that must get resolved permanently.

In business as in life, finding out the root of a problem can save an entire empire. Want to learn more about Root Cause Analysis? Click here to learn more information on our Six Sigma training courses and services.

 

 

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