Is There a Problem?

Is there a problem with root cause analysis? Depends on how you look at it. First, let’s understand what it is. Root Cause Analysis (RCA) is a method of problem solving used for identifying the root causes of faults or problems. A factor is considered a root cause if removal thereof from the problem-fault-sequence prevents the final undesirable event from recurring. Just by the singular title, some look for that single, underlying problem or issue that needs to be resolved. The name itself implies that there is only one root cause, when in reality most problems are usually caused by a complex combination of several factors, some of which are more significant than others.

A Thorough Examination Through Root Cause Analysis

For some, this may be a simple case of semantics. The fact remains that in many cases when using the RCA tool, quality experts find it simple enough to claim victory in a situation with a singular causation. That could be accurate, but more times than not, it simply isn’t the case. An issue that requires attention may have a varied mix of simple and complex causes for failure. To properly address some of these issues requires a structured approach to brainstorming. This will guide the problem-solving team through the various categories of potential causal factors so that the team does not overlook some potentially important causes which lurk in the shadows. The most efficient quality experts will opt for having a cross-functional team help explore the possible causes and potential solution to the problem. Nothing short of a through and exhaustive examination will suffice.

Getting Results That Stick

When the Root Cause Analysis (RCA) is properly exercised, the varied and complex issues will be brought to light. It requires a multi-disciplined approach that is both systematic and based on fact. Achieving long term quality improvements starts with an effective root case analysis. The best approach is a properly designed, sequential set of experiments. If a solution exists, a thorough RCA offers the best chance for thoroughly understanding all the issues involved, no matter how complex or simplistic.

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Teamwork! We all know that great success is the result of great teamwork! Individual effort is important to the equation, but individual effort must be focused on the common goal or outcome. Without everyone working towards the same goal, with the same focus and energy, the desired results will always be elusive. Lean and Six Sigma are methods for quality improvement, each standing on their own merits. However, many organizations struggle with creating a team of the methodologies. Fact is, when they function as a team, the results can be significant.

Implementing the strategies will solely depend on where the comfort level is with each methodology and the desired outcomes. Many start with Lean, as they may view it as the easier process to implement. Others may choose to use Six Sigma first as they wish to gain control of specific processes. When beginning with Lean, using the tools of the methodology to eliminate the eight deadly wastes will achieve significant progress. The Six Sigma methodology can then be used to augment the Lean methodology in addressing process and service issues. Since companies must become more responsive to changing customer needs, faster lead times are essential in all endeavors. Lean is an important complement to Six Sigma and fits well within the Six Sigma DMAIC process. Additionally, the Lean Kaizen approach is a great method that can be used to accelerate the rate of improvements. Some organizations have responded to this dichotomy of approaches by forming a Lean/Six Sigma problem-solving team with specialists in the various aspects of each discipline but with each member cognizant of other’s specialties.

Whatever your choice is, combining the methodologies into a supportive and viable team can yield dynamic results. Lean tools include the 5S system of workplace organization, standard work, one-piece flow, quick change-over, pull systems and total productive maintenance. Six Sigma utilizes DMAIC along with other tools, such as Histograms, Pareto charts, the 5 Why’s, along with Fishbone diagrams to achieve specific results. These tools create a powerful, results driven focus in an organization and will inspire energized teamwork throughout.

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Six Sigma requires teamwork and everyone on the team is important. Everyone has their role, and everyone shares in the credit. If you compare the Six Sigma mindset to that of a team sport, you would be correct. If every company did this, employee morale would be at an all-time high. Think about how every American loves their sports teams; if businesses operated this way, the focus of the employees would move mountains.

The day-to-day work processes takes a team mindset. When using the DMAIC template to improve a process, this is a team effort and should be approached as such. This is the reason that companies who follow the Six Sigma methodologies succeed. Six Sigma has a strong position in taking care of the employees and the customers because they are the most important elements in your business. Without them, you would not have a business.

High morale among employees will increase production, lower turnover, and increase company loyalty two-fold. Every aspect of Six Sigma lends itself to this mindset. Tools such as VOC (Voice Of Customer), brainstorming, and the concept of Root Cause Analysis all lend themselves to a team effort. 

According to the The New York Times, about 75% of employees rate teamwork and collaboration as very important, yet only 18% of employees get evaluated in their performance reviews. Here is a void that Six Sigma can easily fix.

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

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As with all the data in Six Sigma, the first step is to state the problem or issue clearly and concisely. Make sure you state the problem as a problem and not like a solution. Keep in mind that you don’t yet know what solution will work to rid your problem.

Depending on your industry the categories could vary. With your team, agree and pick some categories that you could find the causes for the issue at hand. For example, categories in the service industry could be policy/rules/procedures or equipment/supplies, or perhaps environmental issues.

Make This a Time to Create Solutions as a Team

Then, along with your team, put your heads together and come up with possible causes of the problem. The best tool for finding the deep issue is 5 Whys tool. Keep asking, “Why does this happen” over and over until you can’t get any deeper. Along the way, you will probably make other discoveries in sub-categories, which will help you prevent future similar problems.

Inspire each of your team members to get involved in brainstorming since this is a perfect opportunity to encourage team morale. Too often, supervisors or team leaders look to place the blame on their team, and not to make them part of the solution.

Make sure each team member has a chance to give their opinion as to what they feel are the top three root causes. Record them on the fishbone diagram, and with the backup data vote on the top culprit.

*This is just an example of how you can use a fishbone diagram. It is abbreviated, but it should give you an idea of the mindset you need to have.

Want to dive deeper into fishbone diagrams and how they work? Learn more information today on our Six Sigma training courses and services.

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Usually the explanation doesn’t address as to why the change was so pertinent, as much as it did that there was a change in protocol. So the communication was not effective.  When effective communication occurs, everyone is on the same page and unity is not challenged.

Effective Communication Soothes the Savage Soul 

You remember when you were a child, and your older sibling told you to do something. You would ask why, and he/she said, “Because I said so,” which made you angry, and a fight ensued. Having a valid reason, in other words knowing the whys is important for morale, and more importantly ensures protocol will be followed.

Effective communication is also inclusive to all staff members (unless your company is dealing in top secret government products where no one has all of the information), so treat your staff like a sports team. A sports team knows what it going on at all times, otherwise they won’t win the game.

Having effective communication in your company will also help in remembering what needs to be done, when and how it needs to be done. No one is left out. Can you imagine if the coach of a sports team only gave half the team the strategy they were going to use in the big game for the championship? It doesn’t even sound right, yet many companies do that in business, and then they wonder where they failed.

Six Sigma is All Inclusive

Having the Six Sigma mindset of being efficient and communicative adds value to your business, and will make your entire staff part of your team.

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