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

148 Pages·2014·1.44 MB·English
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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 CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2015 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20140624 International Standard Book Number-13: 978-1-4822-5880-6 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmit- ted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright. com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com 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

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