Root Cause Analysis (Problem Solving)

Course details

All organisations, in both the manufacturing and service sectors, experience problems in their operations. The problems may be technical in nature, or may be people related; the problems may be detected within the manufacturing or service organisation or, more seriously, be identified and reported by the customer. It is important that a well-structured approach to the solution of problems is established. There are well proven methods available to assist organizations to get to the root cause of problems and to develop effective solutions.

Learning Outcomes

On successful completion of this training course, delegates should be able to:

• Contribute in teams to the solution of problems that arise in their own work environment
• Use the problem solving tools to collect and analyse data
• Lead problem solving teams
• Demonstrate understanding of the structure of root cause analysis which leads to the satisfactory elimination of problems

Course Programme

Day 1

Introduction to Continuous Quality Improvement Techniques

Description of the implementation steps of quality improvement including Kaizen, Plan-Do-Check-Act (PDCA), Six Sigma, Genchi Genbutsu, Zero defects, Right First Time, continuous improvement

Seven Basic Quality Tools

Practical tools and techniques used in gathering, graphing, and interpreting data needed to identify and resolve problems. Working with and understanding the use of these tools will form the main part of Day 1 of the course. An important discussion here on the criticality of correctly identifying the type of problem we are dealing with, the tools to be used, and the appropriate approach to be adopted; is the problem of the variables or attributes type?. Tools covered here, including the Process Flow Charts and Cause and Effect Diagrams.

• Histograms – capability analysis - understanding variability in processes, and problems associated with failure to meet specification
• Control Charts – identifying trends in variables and attributes data
• Scatter Diagrams – identifying the relationship between two variables
• Pareto Charts – graphing the frequency and incidence of problems
• Process flow diagrams and process maps – charting the steps in the process – assisting in the understanding of how the process should work, and identifying sources of problems
• Cause and Effect Diagrams – documenting the outcome of the brainstorming process in which the team identifies all possible causes of the problem

Teams

The importance of working in teams when solving problems – structure of the teams – cooperating to solve problems

Poka-Yoke – Mistake Proofing

Techniques used to mistake proof processes against errors occurring, and assisting operators to avoid mistakes and get it Right First Time; Team exercises using Poka-Yoke techniques. Course delegates will be encouraged to use these principles in the practical problem session.

Corrective Action

The corrective-action process – problem identification, brain storming, 5 Why’s techniques, root cause analysis, correction, recurrence control, and verification of effectiveness – overview of the tools to be used on Day 2. Discussion on the problems to be tackled by the teams on Day 2 of the course.

Analysing effectiveness of their implementation

Day 2

Practical Problem Solving Session with the Tutor acting as Team Facilitator

In-House Training course

The group of participants will be divided into smaller teams of approximately 3/5 people. Each team will be allocated an example of a problem from the Company’s operations, and that they are to analyse in the practical session. The examples of the problems that are to be analysed will be discussed between Company Management and the tutor in advance of the training course.

Public Course

The participants will be grouped together in small teams. The tutor will provide a practical case study and detailed instructions on how teams undertake the analysis of a problem, and produce solutions. The tutor will act as facilitator during this team session.

Team Work

The tutor will provide the participants with a detailed procedure set out as a series of steps that is to be followed as they progress through the analysis. The teams will document their work on flip chart sheets or a white board, in the following typical steps:

• Detailed specification of the problem
• Documentation of the background information and evidence that is available including the circumstances surrounding the problem
• Brainstorming of the causes – the participants will document all possible causes under a number of headings including: Equipment, Methods, People, Materials, Environment
• The team will discuss each listed possible cause in detail so that each team member has sufficient understanding to enable them to decide on the likelihood of a link between the cause and the problem
• Short listing of the causes using system of voting provided by the tutor
• Further detailed analysis of the short list using the 5 Why’s technique.
• Conclusion as to the most likely root cause(s) of the problem
• Discussion on the preventive actions to be taken for each of the root causes
• Documentation of the problem , the root causes, and the recommended corrective/preventive actions
• On completion of the team exercises, each team will make a presentation of their work and findings, and the day will finish with a general group discussion on the Root Cause Analysis methodology