Lean Six Sigma Green Belt
Certification Course
Root Cause Analysis
Learning Objectives
By the end of this lesson, you will be able to:
Explain the concept of Root Cause Analysis (RCA)
Create a Cause and Effect Diagram
Interpret a Cause and Effect Matrix
Apply the 5 Whys technique for a problem and find a possible
solution
Introduction
Business does not meet
productivity goal
WHY?
Introduction
Business does not meet
Symptoms
productivity goal
Not using the new
Problem
system
Integration issues Training
Root causes
Root Cause Analysis
Root Cause Analysis (RCA)
Define
Control Measure
Improve Analyze
Evaluate Optimize Validate
Root Cause Analysis (RCA)
Unknown sources of variation
RCA Optimize the process
Implement corrective action
Root Cause Analysis (RCA)
RCA Tools
Cause and Effect Diagram Cause and Effect Matrix 5 Whys Technique
Cause
WHY?
Effect
Root Cause Analysis (RCA)
A root cause is a factor that caused the defect or issue. Removing that factor will
prevent the re-occurrence of the issue.
Cause and Effect Diagram
RCA Tools
Cause and Effect Diagram Cause and Effect Matrix 5 Whys Technique
Cause
WHY?
Effect
Cause and Effect Diagram
The Cause and Effect diagram is used to find the root cause and the potential solutions to a problem.
It is also known as the Fishbone diagram or Ishikawa diagram.
CAUSE EFFECT
Cause and Effect Diagram
CAUSE EFFECT
Material Management Method
Problem
Machine Measurement Man
Determine the main Draw a Cause and
Write the causes on the
classification or Effect diagram with the Brainstorm possible
diagram under the
headings to group the problem at the point of causes of the problem
classifications chosen
causes the central axis line
Cause and Effect Diagram
Cause and Effect diagram for solder defects on a reflow soldering line
Training
Materials Manpower
Skill
Type of Solder Paste Operator
Knowledge
Size
Self-sufficiency
Components Shape
Shifts
Thickness Schedule
Components Packaging Weekends Reflow
Defect
Full reflow
Types of Screen
Batch size Tools
Technology Feeder
Component density
Speed
Fine pitch Oven
Preventive Maintenance Temperature
Methods Machinery
Cause and Effect Matrix
RCA Tools
Cause and Effect Diagram Cause and Effect Matrix 5 Whys Technique
Cause
WHY?
Effect
Cause and Effect Matrix
Process Output Variables
A B C D E
Prioritization Number 4 1 7 11 5 Results %
1 3 4 7 117 33
2 8 5 3 4 96 27
Process Input
3 6 2 46 13
Variables
4 7 5 32 9
5 3 4 65 18
Totals 356 100
Cause and Effect Matrix
Rating of Importance to
Customer
TEMPLATE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Process Inputs
0
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0
16 0
17 0
18 0
19 0
20 0
0
0
Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
The 5 Whys Technique
RCA Tools
Cause and Effect Diagram Cause and Effect Matrix 5 Whys Technique
Cause
WHY?
Effect
The 5 Whys Technique
Identify theSTEPS
PROCESS problem and the problem statement
Arrange for a team brainstorming session
Explain the purpose
Analyze the problem and brainstorm backwards
Ask “Why?” for the answers obtained
???
??
If a problem occurs, it is usually due to the process and not because of a person or team.
The 5 Whys Technique
JAVA
HOUSE
COFFEE
Delivery Van
Erroneous product deliveries
The 5 Whys Technique
EXAMPLE
What is happening? PROBLEM: Delivery of parcels to incorrect addresses
Why is it happening? 1. Incomplete addresses given on the parcel
Why?
2. Complete addresses were not collected
from the customers Why?
3. The addresses were given to the operators
over phone
Why?
4. The operators were unable to gauge if the
addresses were incomplete
5. An official format for capturing delivery Why?
addresses from customers was unavailable
The 5 Whys Technique
Corrective Action
A template for capturing customer delivery information was created.
Points to Remember
Focus on process issues
and not people
WHY?
WHY?
WHY?
WHY?
WHY? Stay within your team’s
control to change
Key Takeaways
A root cause is a factor that caused the defect or issue and
removing that factor will prevent the re-occurrence of the issue.
The Cause and Effect diagram is used to find the root cause and
the potential solutions to a problem.
The Cause and Effect matrix consists of key process input and
output variables to determine which input variables have the
greatest effect on the output variables.
The 5 Whys technique involves asking iterative questions to find
the root cause of the problem.
Knowledge Check
Knowledge
Check
Which of the following is NOT one of the classical cause and effect diagram categories?
1
A. Materials
B. Maintenance
C. Methods
D. Machine
Knowledge
Check
Which of the following is NOT one of the classical cause and effect diagram categories?
1
A. Materials
B. Maintenance
C. Methods
D. Machine
The correct answer is B
Maintenance is considered as an additional category in a classic fishbone diagram. The classical categories are Man,
Material, Method, and Machine.
Knowledge
Check We have an input factor with impact ratings of 3 and 9 on output variables A and B,
respectively. The output variable A has a prioritization value 5 and output B has a
2 prioritization value of 10. What is the score for our input factor?
A. 42
B. 37
C. 105
D. 90
Knowledge
Check We have an input factor with impact ratings of 3 and 9 on output variables A and B,
respectively. The output variable A has a prioritization value 5 and output B has a
2 prioritization value of 10. What is the score for our input factor?
A. 42
B. 37
C. 105
D. 90
The correct answer is C
The score is 3*5 + 9*10 = 105
