Root Cause Analysis: A Step-By-Step Guide to Using the Right Tool at the Right Time

148 Pages·2014·1.44 MB·English

by  Barsalou, Matthew A

Business Management / Quality & Six Sigma
Root Cause Analysis
A Step-By-Step Guide to Using the Right Tool
at the Right Time
Although there are many books on root cause analysis (RCA), most concen-
trate on team actions such as brainstorming and using quality tools to
discuss the failure under investigation. These may be necessary steps
during RCA, but authors often fail to mention the most important member
of an RCA team—the failed part.
Root Cause Analysis: A Step-By-Step Guide to Using the Right Tool at
the Right Time provides authoritative guidance on how to empirically
investigate quality failures using scientific method in the form of cycles of
plan-do-check-act (PDCA), supported by the use of quality tools.
Focusing on the use of proven quality tools to empirically investigate
issues, the book starts by describing the theoretical background behind
using the scientific method and quality tools for RCA. Next, it supplies
step-by-step instructions for performing RCA with the tools discussed in
the first section. The book’s clear examples illustrate how to integrate
PDCA with the scientific method and quality tools when investigating
real-world quality failures.
This RCA guide provides root cause investigators with a tool kit for the
quick and accurate selection of the appropriate tool during a root cause
investigation. It includes an appendix with a guide to tool selection based
on the intended use of the tool. There is also an appendix that defines the
terminology used in the book.
After reading this book, you will understand how to integrate the scientific
method, quality tools, and statistics, in the form of exploratory data analy-
sis, to build a picture of the actual situation under investigation that will lead
you to the true root cause of an event.
The tools and concepts presented in the text are appropriate for profes-
sionals in both the manufacturing and service industries.
A Step-By-Step Guide to Using the
Right Tool at the Right Time
K24153
Matthew A. Barsalou
BARSALOU R O O T C A U S E A N A L Y S I S
Root Cause
Analysis
Root Cause
Analysis
A Step-By-Step Guide to Using the
Right Tool at the Right Time
Matthew A. Barsalou
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A P R O D U C T I V I T Y P R E S S B O O K
Root Cause
Analysis
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Version Date: 20140624
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To my wife Elsa for her patience while I wrote this book
and my son Leander who was born as I was starting it.
Contents
Preface ....................................................................................................xi
Introduction ........................................................................................ xiii
About the Author ................................................................................xvii
Section i introduction to Root cause Analysis
chapter 1 The Scientific Method and Root Cause Analysis ............. 3
chapter 2 The Classic Seven Quality Tools for Root Cause
Analysis ............................................................................. 17
chapter 3 The Seven Management Tools ......................................... 27
chapter 4 Other Tools for Root Cause Analysis .............................. 33
chapter 5 Exploratory Data Analysis and Root Cause Analysis .... 39
chapter 6 Customer Complaint-R elated Root Cause Analysis ...... 45
chapter 7 Example of a Root Cause Analysis .................................. 51
Section ii Root cause Analysis Quick Reference
chapter 8 Introduction to Root Cause Analysis ............................. 57
Introduction ...............................................................................57
Key Points ..............................................................................58
vii
viii • Contents
chapter 9 The Science of Root Cause Analysis ............................... 59
Hypothesis as a Basis for New Knowledge ............................59
Key Points ............................................................................. 60
Scientifc Method and Root Cause Analysis ..........................61
Key Points ..............................................................................62
Experimentation for Root Cause Analysis ............................ 64
Key Points ..............................................................................65
chapter 10 The Classic Seven Quality Tools ..................................... 69
Introduction ...............................................................................69
Ishikawa Diagram .....................................................................69
Key Points ..............................................................................70
Check Sheet ................................................................................71
Check Sheet with Tally Marks ............................................71
Key Points ..............................................................................73
Check Sheet with Graphical Representations ...................73
Key Points ..............................................................................74
Run Charts .................................................................................75
Key Points ..............................................................................75
Histogram ...................................................................................76
Key Points ..............................................................................76
Pareto Chart ...............................................................................77
Key Points ..............................................................................78
Scatter Plot ..................................................................................79
Key Points ..............................................................................79
Flowchart ................................................................................... 80
Key Points ............................................................................. 80
chapter 11 The Seven Management Tools ......................................... 83
Introduction ...............................................................................83
Matrix Diagram .........................................................................83
Key Points ..............................................................................83
Activity Network Diagram ..................................................... 84
Key Points ..............................................................................85
Prioritization Matrix ................................................................ 86
Key Points ............................................................................. 86