Root Cause Analysis | Arrelic Insights
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The document discusses various root cause analysis tools including 5-Why analysis, thought mapping, process mapping, cause-and-effect matrices, FMEA, process behavior charts, and data mining. 5-Why analysis involves repeatedly asking "why" to identify the root causes, while thought mapping explores multiple influences without assuming a single cause. Process mapping catalogs variables and process behavior charts detect shifts or outliers in process data. Combined, these tools provide thorough root cause identification and analysis.
Root Cause Analysis | Arrelic Insights
- 1. R O O T C A U S E F A I L U R E A N A L Y S I S Ar re lic INS IG HT S w w w . a r r e l i c . c o m
- 2. I N T R O D U C T I O N So m e b a sic p r i n c i p l e s a b o u t r o o t c a us e a n a ly si s. Th e f i r st , f o r t h e m o s t p a r t , t h i n g s h a p p e n f o r a r ea so n , a n d w e c a l l t h o s e r ea so n s c a us es . Th e se c o n d , i s t h a t n o t a l l c a us es a r e e q u a l ly i m p o r t a n t . So m e a r e m u c h m o r e i m p o r t a n t t h a n o t h e r s. A n d f i n a l ly , i f w e c a n u n d e r st a n d r o o t c a us es a n d c o n t r ol t h e m t h e n w e c a n g e t t h e r es u l t s t h a t w e l i k e o u t of o u r p r o c e s s . O n e of t h e c o m m o n l y us e d r o o t c a us e a n a ly si s t o o l s , i s w h a t w e c a l l t h e t w o - y ea r - o l d a p p r o a c h . Yo u k n o w , i f yo u ' ve ev er h a d t h e p l e a su r e of h a v i n g a t w o - y ea r - o l d i n yo u r l i f e, yo u k n o w t h e y a sk, " W h y ? " a l o t . So, t h e p o i n t of t h e ex er cis es i s t o a sk w h y a t le a st f i v e t i m e s . H e r e' s a n ex a m p l e t h a t so m e t i m e s i s us e d . H e y , t h e r e' s o il o n t h e f l o o r . Th e f i r st i m m e d i a t e r ea c t i o n i s, w e l l , l e t ' s c l e a n i t u p so w e h a ve a c l e a n w o r k p l a c e . B u t , i t ' s b e t t e r t o a s k, w h y i s t h e r e o il o n t h e f l o o r ? W e l l , t h e r e' s o il o n t h e f l o o r b e c a us e t h e m a c h i n e ov er h e a d i s le a k i n g . O h , w h y i s t h e m a c h i n e ov er h e a d le a ky ? W e l l , t h e m a c h i n e ov er h e a d i s le a k i n g b e c a us e i t ' s g o t a b a d g a sk e t . W h y d o e s i t h a ve a b a d g a sk e t ? B e c a us e w e h a ve a p o l i c y a n d w e g o t s u c h a g o o d d e a l o n a la r g e b a t c h of t h e s e l o w q u a l i ty g a sk e t s Th e r e' s a n o t h e r t o o l , t h a t si m i l a r i n sp i r i t , t o t h e Fi ve - W h y a p p r o a c h a n d t h a t so m e t i m e s i s c a l l e d V a r ia t i o n B r ea k d o w n or i t ' s so m e t i m e s c a l l e d t h e Th o u g h t M a p . A l l i t d o e s i s, l i k e Fi v e W h y s, k e e p s a sk i n g w h a t i n f l u e n c e s t h i s or w h y d o e s t h i s h a p p e n . B u t i t d o e s n o t m a k e t h e a s s u m p t i o n t h a t i t ' s a l w a ys jus t o n e c a us e. So o n e q u e s t i o n i s, w h a t m i g h t a f f e c t t h e a m o u n t of t i m e t h a t i t t a k es m e t o g e t t o w o r k i n t h e m o r n i n g ? W e l l , o f f - h a n d I c a n t h i n k of s o m e d i f f e r e n t t h i n g s w e m i g h t c h o o s e d i f f e r e n t r o u t e s . For ex a m p l e , w e m i g h t h a ve t h e sc e n i c r o u t e , or t h e f r e e w a y r o u t e , or w e m i g h t p r e f e r t h e r o u t e p a s t t h e c o f f e e s h o p . C er t a i n l y t h e lev el of tr a f f ic o n t h e r o a d i s g o i n g t o m a k e a d i f f e r e n c e . H o w ea r ly w e le a ve i s g o i n g t o m a k e a d i f f e r e n c e a n d w e m i g h t c h o o s e d i f f e r e n t m o d e s of tr a ns p o r t a t i o n . Th a t ' l l a f f e c t h o w l o n g i t t a k es m e t o g e t t o w o r k T h e n , f o r s o m e of t h e s e, o n e lev el i s a l l y o u n e e d t o g o t o . F or ex a m p l e , w e m a y o n l y h a ve t h r e e r o u t e s t o c h o o s e f r o m a n d so t h i s tr e e e n d s r i g h t h e r e b u t f o r t h e a m o u n t of tr a f f ic o n t h e r o a d , w e l l , t h a t m i g h t b e c a us e d b y t h e n u m b e r of a c c i d e n t s , b y t h e r o a d c o n d i t i o n s , b y t h e a m o u n t of r o a d w o r k t h a t ' s g o i n g o n , or b y t h e t i m e of d a y. I f w e c a n a vo i d r us h h o u r , so m u c h t h e b e t t e r . Th e n yo u a sk, w h a t a f f e c t s r o a d c o n d i t i o n s a n d t h e r o a d c o n d i t i o n s a r e m o s t ly a f f e c t e d . W e t h i n k b y t h e w e a t h e r , a n d i t c a n b e sn o w y , or i t c a n b e r a i n i e r , i t c a n b e c l e a r . So, b a si c a l ly yo u g o t h r o u g h a n d m a k e t h i s l i t t l e c h a r t t h a t l e t s t h e c a us es f l o w d o w n , a n d t h e l o w e s t lev el i t e m s o n t h e c h a r t a r e. Th e n w h a t yo u w o u l d c o n s i d e r yo u r r o o t c a us es . N o w , i n so m e c a ses yo u ' r e g o i n g t o c o m e u p a g a ins t o n e of t h e s e w h e r e yo u sa y w e d o n ' t k n o w , a n d t h a t ' s a g o o d p l a c e t o st a r t a n in v es t i g a t i o n .
- 3. A n o t h e r t o o l t h a t ' s ver y us e f u l i s t h e P a r e t o C h a r t . This n e s t e d P a r e t o C h a r t i s o u r p a t e n t e d in v e n t i o n , a n d i t ' s v er y h a n d y f o r f i n d i n g w h e r e, a n d w h e n , a n d b y w h o m , d e f e c t s w e r e m a d e . T h a t ' s a r ea l ly g o o d s i m p l e r o o t c a us e a n a ly si s t o o l . For a ver y t h o r o u g h r o o t c a us e a n a ly si s, w e us e a tr io of t o o l s i n c o n c e r t a n d t h a t st a r ts w i t h t h e p r o c e s s m a p . O f c o u r se, i n t h e p r o c e s s m a p o n e of t h e i m p o r t a n t t h i n g s t h a t y o u ' r e d o i n g i s l o o k i n g a t yo u r k n o b va r ia b l e s . Th e i n p u t va r ia b l e s t h a t m a k e t h i n g s w h a t t h e y a r e a n d c a t a l o g i n g a l l of t h o s e. Th e n w e n e x t m o v e t o t h e c a us e - a n d - e f f e c t m a tr ix b e c a us e ea r l ier w e sa i d n o t a l l va r ia b l e s w e r e i m p o r t a n t , n o t a l l c a us es a r e e q u a l ly i m p o r t a n t , a n d i n t h e c a us e - a n d - e f f e c t m a tr ix , w e p r io r i t iz e a n d b r i n g t o t h e su r fa c e t h o s e v a r ia b l e s t h a t a r e l i k e l y t o b e m o s t i n f l u e n t i a l . Fi n a l ly , w e g o t o t h e FM E A a n d d r i l l d o w n t o t a k e a g o o d l o o k a t t h e va r ia b l e s t h a t t h e c a us e - a n d - e f f e c t m a tr ix i n d i c a t e d w e r e l i k e l y t o b e m o s t i m p o r t a n t , a n d t h a t ' s a ver y n i c e r o o t c a us e a n a ly si s. For a r o o t c a us e a n a ly si s t o o l w i t h a l i t t l e b i t m o r e m a t h e m a t i c a l r i g o r , w e c a n t u r n t o a p r o c e s s b e h a vio r c h a r t or a s so m e p e o p l e c a l l t h e m c o n t r ol c h a r ts . A l l t h a t d o e s i s p u t yo u r d a t a i n t h e or d e r t h a t t h e y h a p p e n e d . I t p r ov i d e s a c e n t e r l i n e , w h i c h i s t h e a v er a g e or s o m e t i m e s t h e m e d i a n, a n d i t p r ov i d e s so m e l i m i t s h e r e t h a t d e f i n e w h a t c o n s t i t u t e s a n u n u s u a l ev e n t . I f w e g e t s o m e t h i n g l i k e t h i s , w h e r e w e h a v e g o t a p o i n t o u t of l i m i t or i f I ' ve g o t sh i f t s i n m y p r o c e s s, t h e r u l e s of t h e p r o c e s s b e h a vio r c h a r t w i l l d e t e c t t h o s e. Th e n w e h a v e a v er y g o o d b a si s f o r g o i n g a n d a sk i n g , w h a t w a s g o i n g o n r i g h t h e r e.
- 4. Su m m a ry To su m m a riz e , in t he 5- W hy an alysis, t he appr o ach wo u ld alwa ys be W ha t ha ppe n e d tha t ca u se d t hi s t o ha ppe n . Thi s o t he r t hi n g isn ' t ve ry in t e re stin g be ca u se st at ist ica l ly it ' s al l t he same . W e re ally ca n ' t t e l l o n e o f t he se po in t s fro m an o the r, bu t thi s o n e is di ffe re n t . W ha t ma ke s it in t e re stin g is it is so rt o f t he an ce st o r o f t he ro o t ca u se an al ysis t o o ls is wha t we ca l l da ta mi n in g , o r so me t ime s e xpl o rat o ry da t a an al ysis, an d t ha t' s ju st a wa y o f fin di n g t he hi dde n re l at io n shi ps in yo u r da t a. No w, t hi s ma y l o o k a lit tl e fo rbi d d i n g , bu t be lie ve me , it ' s n o t . It ' s e xt re me ly sim p l e t o u se . W ha t we ha ve do wn he re is so me da t a t ha t we ha ve t ake n we ha ve ke pt t rack o f ho w ma n y po u n ds o f o n io n s we g o t an d as in pu t variabl e s o r ca u se s, the te m p e rat u re , an d the wa t e r, an d the type o f so il t ha t we pl an t e d in , an d whe the r o r n o t we u se d t o pe stici de . W ha t t he co m p u te r t he n do e s is it bu il ds u s a m o de l tha t we ca n pl ay wi th an d we ca n slide t hi s ba ck an d fo rt h. He re ' s o u r averag e ha rve st we i g ht rig ht he re , 2386, an d if we g e t wa rme r we at he r, wha t ha ppe n s if it g o e s u p t o 2528. If I pl an t in san dy so il, I g e t o n l y 240 po u n ds . So , t hi s g i ve s me a we al t h o f in fo rma t io n abo u t t he re l at io n shi p be t we e n t he ro o t ca u se s an d t he o u t co me s t ha t we g e t . Tha t sho u l d g ive yo u so me g o o d ide as abo u t ro o t ca u se an alysis t o o l s an d ho w t o u se t he m .
- 5. Disclaimer The information contained herein is of a general nature and is not intended to address the circumstances of any particular individual or entity. Although we endeavour to provide accurate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act on such information without appropriate professional advice after a thorough examination of the particular situation. In this regard, Arrelic has no responsibility for the consequences hereof and no liability. About Arrelic Arrelic is a fast-growing deep-tech firm aiming to bring the next level of IoT based sensor technology to transform the mode of manufacturing operation and maintenance practice of various industries with extensive expertise in Reliability Engineering, Predictive Maintenance, Industrial Internet of Things (IIoT) Sensors, Machine Learning and Artificial Intelligence. We provide a single ecosystem for catering all industry needs from Consulting to IoT and Analytics as well as providing Training and Development courses for different stakeholders. We aim to help manufacturing industries to improve their overall plant productivity, reliability and minimize total production cost by 25-30% by eliminating machine downtime, lightening management decisions by analyzing the machine data with right mind and expertise; for a worry free operation ©2018 Arrelic Reliability Private Limited ・All rights reserved . Arrelic, Arlytic, PdMAAS, are trademarks of Arrelic . No part of this document may be distributed, reproduced or posted without the express written permission of Arrelic. DesignedinIndia|Arrelic GETTING IN TOUCH WITH US If you have any questions or would like any further information our products and services or if you would like to discuss a potential initiative, you feel we could help us with, please don’t hesitate to contact us.