Operations Excellence Tool #1 - Root Cause Analysis

Implementing operational excellence has many dimensions, and may tools along the journey to success. Sometimes manufacturing operations get caught up in the "flavor of the month," fancy buzz words, or other hybrid tools (lean-six sigma) based on the latest book published on the subject. As always, we like to focus on the problem at hand and use the appropriate tools rather than implement a specific tool or program - "we are going to implement lean this year" never made much sense to us.

With that said, there is one tool that we believe is the most effective way of achieving operational excellence, and frequently overlooked in the search for a more "sexy" approach. The most powerful tool for achieving operational excellence, proactive operations, and effective design is root cause analysis. There are numerous methodologies for performing root cause analysis. Each has their own advantages, but the most important aspect is the formalized, structured approach rather than the specific investigative tools. Sure, we have our preferences, but if an organization has already trained personnel and is already using a root cause analysis methodology we say great - as long is it is done well, use it as a cornerstone to your preventive and operational excellence efforts.

The basic steps in an effective root cause analysis should include:

- What happened? Describe the effects.
- Why did it happen? Describe at least two potential causes.
- Repeat the process until the root cause is determined (usually five cycles).

Some of our suggestions for insuring an effective analysis are:

- Causes may not present themselves in order of occurrence - so don't expect it.
- The sequence of causes will likely branch, so chart the cause/effect. Wishbone charting is useful for this.
- Each event may have many causes, but eliminating the root cause will prevent the event.
- It may be useful to work backward from the event.
- Document acceptances and rejections of root causes.
- Correlate primary effect to causes.

Most root causes can be boiled down to three areas - people, equipment, and procedures. Improve the people through training and leadership; the equipment through better design, operation, and maintenance practices; and the procedures; and good things will happen! If you don't, bad things will happen.

Synchronous experts are ready to help you set a solid foundation for your root cause analysis efforts in your organization. Send us an information request to Sales@SynchronousLLC.com , or review our complete portfolio of services at our web site www.SynchronousLLC.com