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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6 Power Tools of Lean Six Sigma

The term Lean six sigma is not complex at all and is very straight forward. It is simply the combination of lean manufacturing and Six Sigma to form a unique system that eliminates waste. Adopting this method allows a business to increase production while streamlining their manufacturing process.

The Main Tools of Lean Six Sigma Every Organization Must Be Aware Of

A concept as massive as this one would be very hard to understand or even implement if they weren’t any tools to help organizations out. If an organization using Lean Six Sigma wants to get the best results, there are a number of tools which they must be aware of. Below are 6 of the most popular that can help a business get started when using Lean Six Sigma

 1. The 5 Whys

Organizations can use the five why to understand the cause of the problem. How it works is very easy and can be implemented in the manner below.

• An organization can write down the problems they are facing so that all the employees are aware and focused on dealing with it
• The organization can ask themselves why the problems keep on occurring
• If the first answer an organization has is not the cause of the issues, there is no need to ask again
• An organization can repeat this step up to five times until they find out what the cause of the problem really is in their ranks

2. 5S System

The 5S system allows an organization to organize materials for quick and easy access. This also makes sure that they are better maintained and does a wonderful job eliminating waste that is produced from tools in not so pleasant working order.

These 5S’s are:

• Sort Take out all unneeded item and only leave those that are needed to get the job done.
• Set in order label and organize items properly
• Shine inspect as well as clear work areas every day
• Standardize Write down a list of standards employees need to follow as far as shine, sort and set in order are concerned
• Sustain An organization has to apply the standards they have set and make sure employees follow them religiously

3. Kaizen

This is a very popular tool and it refers to the practice where an organization continuously improves its manufacturing process by introducing new methods. Kaizen helps management and employees get involved especially when it comes to making improvement in the manufacturing side of things. Waste is significantly reduced since everyone is involved plus the smallest of mistakes are easily spotted and dealt with.

4. Failure Modes and Effects Analysis

This tool, which is known as FMEA for short, helps an organization highlight any weakness early before things get worse. The development of this method goes as far back as the 1950s and it can be used to identify failure modes as well as review assemblies and components.

5. Pareto Chart

This is a graphical representation of information which allows an organization using Lean Six Sigma to highlight any major issues in their operation. The X-axis on the graph shows a group of response variable which is represented by bars e.g. machine parts. The Y-axis, on the other hand, shows a defect frequency and a cumulative percentage.

6. Poka Yoke

This is a Japanese term which means mistake proofing when translated to English. This is where employees highlight any mistakes that have occurred as a result of human error during production.

If an organization decides that Lean Six Sigma is the way forward for them, the 6 tools mentioned above need to be used properly. There is no denying that these tools do work and will help an organization pinpoint problems before they get worse. The most successful organizations in the world are successful because these tools help them massively. Major problems are avoided because they are tackled in their infant stage before they spread.

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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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The 7 quality tools include:

1. Stratification (Divide & Conquer): Here data is divided into smaller subcategories. These subcategories are divided into groups based on the information that they most cover, and the specific information given in these subgroups help solve an existing issue.
2. Histogram: These contain information on the frequency of specific occurrences that have to do with the issue needed to be resolved.
3. Check Sheet: An easy way to display both qualitative and quantitative data that is gathered for analysis; also called a tally sheet. This is great in understanding where in the progress that defect patterns happen.
4. Cause & Effect Chart (Fishbone or Ishikawa Diagram): This diagram is extremely useful in problem solutions as well as identifying the root causes for an issue.
5. Pareto Chart (80-20 Principle): This chart is based on 20% of causes resulting in 80% of effects. The Pareto charts help us visualize through the chart that the majority of end results come from a minority of actions or causes for defects.
6. Scatter Diagram: This is a mathematical chart that correlates a set of two variables for specific data.
7. Control Chart (Shewhart Chart): This is a great tool for observing all pertinent processes over time. This tool makes it easy to see the variation and pinpoint its occurrence.

These quality control tools help in gathering important data that will make quality improvement based on facts and not on arbitrary guesses. Keep in mind that the Voice of Customer (VOC) is of utmost importance since fulfilling the customer’s requirements is the reason you are in business, and without your customers, you won’t have a business or company.

For more information on our Six Sigma training courses or services, please visit 6sigma.com.

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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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Top 7 Six Sigma Quality Tools –

1.     Control Chart – One of Your Essential Control Tools

Quality improvement involves a lot of testing and documentation. As such, a control chart is a highly effective method by which to monitor and maintain statistical control. Control charts will help you remain aware of your measurements and limits, as well as pin down the causes of variation.

2.     Cause and Effect Diagram

Also known as Fishbone or Ishikawa Diagrams, CEDs give your employees the freedom to interrogate problems for their possible causes. Every fishbone branching off the spine of the diagram represents a different category, allowing you to question multiple lines of inquiry at once.

3.     Histograms – For Graphical Data Display

One of Six Sigma’s most commonly used tools, histograms display and make sense of data. You should use them to show probability distribution in graph form. Histograms are also useful for indicating the frequency with which factors affecting quality or process improvement appear. Histograms, like Pareto diagrams, represent data vertically and horizontally.

4.     Check Sheet – Asks the 5 Whys

Another frequently used quality tool, you should use check sheets for data collection. Check sheets collect and collate data in real time, when and where your data is located. You can spot problems and highlight trends with ease, as check sheets make analysis simpler. Taking the form of a physical document or as a computer program, check sheets allow you to collect both quantitative and qualitative data. Check sheets become tally sheets when dealing with quantitative data. Check sheets involve collating all relevant project or process information. Questions of Who, What, When, Where, and Why are used to measure probability distribution and quantify variation.

5.     Stratification

Six Sigma practitioners use stratification to classify data systematically. Stratification arranges information according to suitable categories, which you should devise for yourself, such as process, time, place, frequency, etc. Stratification is sometimes known as a flowchart and provides a visual template for how processes work. They can also identify your process customers.

6.     Scatter Diagram – Critical Quality Tools

A critical quality tool in Six Sigma, scatter diagrams allow you to show how two factors are related. Like cause and effect diagrams, scatter diagrams can display both causation and correlation, as well as the degree to which both appear. You can also test potential cause and effect relationships between multiple variables.

7.     Pareto Chart

Known as ABC analysis, Pareto charts are a classic of quality improvement work. Pareto charts are one of Six Sigma’s most highly utilized tools and used by companies all over the world. Pareto charts enable you to prioritize your most critical problems and the factors contributing to them. If a factor affects your business in a negative way, Pareto charts can help distinguish between the vital few and your trivial many are useful for identifying the most significant issues to tackle first.

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What Does Lean Focus On?

Lean focuses on reducing the eight types of waste (Muda).  Defects, overproduction, waiting, non-utilized talent, waste from transportation, inventory waste, waste from motion, unnecessary processing. Additionally, Lean principles aim to reduce waste by identifying and eliminating it. Lean also improves production by maximizing flow and identifying non-value-adding steps you should remove. Anything that does not add value for the customer is a potential threat to production. As such, Lean uses a holistic approach that aims to build a culture of continuous improvement and in-depth analysis.

Lean Principles, Tools, and Techniques

• PDCA. Standing for Plan, Do, Check, Act, PDCA is a rapid cycle-based strategy used to drive process improvement.

• 5S is a 5-step method for creating and maintaining an intuitive and efficient workplace. The 5 Ss stand for Sort, Set In Order, Shine, Standardize, Sustain.

• 8 Types of Waste. Lean aims to eliminate the eight waste types: defects, overproduction, waiting, non-utilized talent, waste from transportation, inventory waste, waste from motion, and unnecessary

• Value Stream Maps. VSMs are a visual method for displaying the key process steps in production.

• Flow is the unhindered movement of a process.

• Pull describes how customer demand is used to dictate process flow, i.e. what the customer wants, or might want, determines what a company produces.

What does Six Sigma Focus On?

Six Sigma and Lean share many similarities. As such, they complement each other very well. However, Six Sigma focuses primarily on reducing variation, just one of the seven types of waste Lean tackles. Six Sigma is used to complete improvement projects, aimed at solving process issues. It is also highly data-oriented, involving validation of hypotheses using statistics. Six Sigma knowledge is classified using a belt-based hierarchy styled on martial arts (Yellow, Green, Black, and Master Black Belt). The higher the belt, the more adept you are at using Six Sigma. Furthermore, one of Six Sigma’s primary tools is a 5-step method with which to complete improvement projects.

Six Sigma Ideas, Tools, and Techniques

• DMAIC. This 5-step method uses the following steps, Define, Measure, Analyze, Improve, and Control to improve production processes. Furthermore, DMAIC also allows you to identify the problem and develop creative solutions through deep analysis.

• Project Charter. Six Sigma uses a single-page document to outline the process issue, project goal, scope, and a timeline. Moreover, the charter forms an essential framework for the trajectory of an improvement project.

• Pareto Chart. Pareto Charts display information about potential causes of process issues in a cascading bar chart format. Additionally, you should also organize problems from largest to smallest.

• Hypothesis Testing. Hypothesis Testing is a way of providing statistical precision to root causes of process problems, so you can make the best decisions.

• Design of Experiments. Methods of controlled testing, with which to assess how efficient processes are. DoE also allows you to select the best conditions, materials, and methods for each.

• Statistical Process Control. SPC enables you to monitor your processes, ensuring they consistently satisfy customer demand.

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