1. Root cause analysis

2. Also known as fish-bone diagram

3. Root cause analysis
In any organization numerous problems exist in all facets of its activities. The efficiency and survival of the organization depends on how promptly these problems are recognized and their root causes are isolated and eliminated.

4. Root cause analysis
A systematic analysis of each potential problem area should be carried out to recognize the root causes which are responsible for creating the problem. Such analysis is called Root Cause Analysis.

5. Possible root causes for non conformance/ defects

6. Machine factors Inadequate process capability
Incorrectly designed tooling
Poor maintenance
Equipment effected by environmental factors such as heat, humidity etc.

7. Material factors Use of untested materials Mix-up of materials
Substandard material accepted on concession because of non-availability of correct material
Inconsistency in specifications on the part of vendors

8. Men factors Incorrect knowledge of setting up machines
Undue rush by the operator to achieve quality targets
Lack of understanding of drawing instructions relating to a process
Operator does not posses requisite skill for operating machines

9. Method factors Inadequate process controls
Non availability of proper test equipments
Test equipment out of calibration
Vague inspection/ testing instructions

10. Cause and effect diagram
Cause and effect diagram (also known as ishikawa diagram or fishbone diagram) is an analysis tool to analyze many potential or actual causes of a problem in a systematic way. It is a very effective way of improving the quality of the product or service.

11. Cause & Effect diagram - Major and subsidiary causes
Material
Methods
Environment
Noise level
Procedures
Assemblies
Temperature
Humidity
Consumables
Components
Accounting
Suppliers
Lighting
Policies
Quality
Variability
Instruments
Training
Experience
Tests
Technology
Tooling
Attitude
Gauging
Skill
Fixtures
Counting
Men
Machine
Measurement

12. Example of Cause & Effect diagram - Low operating profit
Material
Methods
Environment
Inadequate
process control
High Noise level
High lead time
poor review
system
Heat
High inventory
Poor QC
Poor quality
of vendors
Poor Lighting
Poor MIS
Low
operating
profit
High
variation
Inadequate
Instruments
Inadequate
Training
Lack
of Experience
Old machines
Poor
Maintenance
No SPC
Low
motivation
Frequent
breakdowns
Inadequate
measurement
Men
Machine
Measurement

13. Click on the boxes to enter your cause & effect
Material
Methods
Environment
Click to enter
click
Men
Machine
Measurement