No matter how well you run your factory, bottlenecks, and quality control issues are sometimes unavoidable. This affects efficiency, costs, and customer satisfaction rates. Addressing the symptoms alone isn’t enough to solve the issue. Managers need to understand what’s causing the problem and address the underlying issues. This is where lean tools like root cause analysis come in.
Keep reading to discover why this lean problem-solving method is essential for continuous improvement and operational excellence, and learn the key steps to putting it into practice.
What is Root Cause Analysis?
Root Cause Analysis is one of the most effective lean tools for problem-solving. It involves analyzing problems to uncover their underlying causes. You can use this structured problem-solving method to understand machine-specific issues or analyze bottlenecks in workflow between departments.
Why Root Cause Analysis Matters for Manufacturers
Conducting a thorough root cause analysis helps factory managers identify the factors contributing to a problem. This helps focus on the ‘Why’ and ‘How’ behind each issue. It’s important to note that there may be more than one contributing factor.
Once identified, managers can address the underlying issues and take corrective action to keep them from recurring. In some cases, it may involve modifying and improving existing processes. Or, you might feel the need to institute new Standard Operating Procedures (SOPs). In the long term, this improves quality standards and drives continuous improvement.
Root cause analysis also improves cost efficiency by reducing machine downtime and the risk of defects.
Popular Root Cause Analysis Tools and Techniques
There are many different ways factories may approach Root Cause Analysis. Some of the most commonly used lean tools for problem-solving include:
The 5 Whys
The 5 Whys method requires asking the question, ‘Why’ 5-times. That said, sometimes, you may find it enough to ask the question twice, while at other times, you might need to ask it up to a dozen times.
Here’s an example. Let’s say a machine stops working. You can understand the root cause by asking the following questions:
- Why did the machine stop working? – because the conveyor belt wasn’t working.
- Why was the conveyor belt not working? – because it wasn’t getting enough power.
- Why wasn’t it getting enough power? – because the motor stopped working.
- Why did the motor stop working? – because it was overloaded.
- Why was the motor overloaded? – because there are no SOPs on motor usage.
Hence, by making work instructions for the motor available to employees, you can solve the issue and keep it from recurring.
Fishbone/ Ishikawa Diagrams
This is a visual root cause analysis tool that gets its name from the shape of the diagram. Write the problem you wish to study along a horizontal line or the fish’s spine. Then draw lines out from the fish spine to document influential factors categorized by materials, machinery, methods, skills, measurement, management, and so on. You can then document all possible causes of the issue along the appropriate ‘fishbone’.
Failure Mode and Effects Analysis (FMEA)
FMEA is a systematic process to proactively identify potential issues with a product or system. The process allows analysts to prioritize failures according to their severity, frequency, and ease of detection. In turn, you can use the results of this analysis to identify actions that eliminate or reduce failures. FMEA also focuses on documenting existing knowledge about failure throughout the product/ service lifecycle to drive continuous improvement.
Scatter Diagrams
Scatter diagrams are visual, quantitative methods used to identify factors contributing to an issue and uncover relationships between them. You can use scatter diagrams as a secondary step to tools like the 5 Whys or Fishbone diagram analysis. In these diagrams, plot independent variables (the potential causes) along the x-axis, and plot the dependent variable (the observed problem) on the y-axis. This graphical representation helps identify relationships and confirm causal links.
Conduct a Root Cause Analysis on the Shop Floor (a Step-by-Step Guide)
Irrespective of the tool chosen and the problem being addressed, you should follow this 6-step process to conduct a root cause analysis:
- Define the problem
This is the broadest stage of problem-solving. Ask questions targeted at defining the problem and identifying it as an urgent issue, bottleneck, etc.
- Collect data
This step is all about gathering quantitative and qualitative data as potential factors that could contribute to a problem. Collect data by interviewing employees and customers, IoT devices, etc.
- Identify possible causes
Study the data collected to distinguish between symptoms of a problem and causal factors. You can use the common root cause analysis tools listed above at this stage.
- Design corrections
Once the root cause of an issue has been identified, craft an effective solution. This may be in the form of employee training, modifying machine operations, changing the floor layout, and so on.
- Implement solutions
Next, implement the planned solutions as a small pilot project. On successful completion of the pilot project, you can then implement the corrected actions across the department/ factory floor.
- Test and validate
Lastly, you must audit the solutions to validate their effectiveness. This may require regular monitoring or making adjustments to make the corrections more effective.
How does Root Cause Analysis Give your Factory a Competitive Advantage?
Give your organization a significant competitive advantage by systematically identifying and correcting the underlying causes of product/process issues root cause analysis. Here’s how:
- It helps identify bottlenecks and streamline operations for smoother workflows and faster time to market.
- It cuts down on material waste as well as the need for rework thereby optimizing costs.
- Addressing underlying causal factors reduces the risk of unplanned downtime and increases productivity.
- By implementing solutions with lasting effects, root cause analysis minimizes quality issues and improves product quality. This increases customer satisfaction rates.
- This proactive form of problem-solving drives data-driven decisions and empowers employers to take ownership of their workstations and tasks.
Why is Root Cause Analysis Key for Continuous Improvement?
Root Cause Analysis drives continuous improvement by ensuring organizations address the underlying causes of an issue rather than the symptoms. As mentioned above, this improves overall efficiency and brings about long-lasting performance improvements. It also helps factories keep the identified issue from happening again. Further, it helps organizations move beyond temporary fixes.
These effects create a culture of ongoing learning. They also build a sense of responsibility in the team and encourage proactive problem-solving.
Getting Started with Root Cause Analysis in Your Factory
From fashion to automobile manufacturing, root cause analysis is beneficial to all factory environments. That said, for it to be effective, root cause analysis must become a part of your regular operations. Having the right tools makes this easier.
Take digital visual management boards in tools like fabriq for example. It can play several roles ranging from data collection to supporting communication and brainstorming sessions. The user-friendly interface empowers teams to run root cause analysis tools, quickly pinpoint underlying pain points, and design data-driven corrective actions. Once a solution is designed, it makes sharing information easier which helps keep everyone on the same page.
Reach out for a demo today and take the first step toward smarter problem-solving with fabriq.
