root cause analysis. agenda purpose how it works rca at your shop questions
Post on 18-Dec-2015
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ROOT CAUSE ANALYSIS
AGENDA
Purpose
How it works
RCA at your shop
Questions
ABOUT
• Continuous Improvement• My experience• These principles working for your shop
ROOT CAUSE ANALYSIS
PURPOSE: find the causes of a problem and implement the best solutions to keep that problem from recurring.
HOW IT WORKS
Define a problem
Assemble a team
Cause & effect chart
Identify Solutions
Implement best solutions
Measure & Validate
COLLECTING DATA
• Historical data• Time studies• Surveys• Shadowing• Traveling
Wat
er B
ottle
Bos
ses
Tire C
leara
nce
Braze
Axle to
Cro
wn
Cosm
etic
Pin Hole
s
DO Sym
met
ry
Brake
Bos
s Spa
cing
Burrs
Dents
/Ding
s
Crown
Race
Dia
Dropo
ut S
pacin
gW
eld0
100
200
300
400
500
600
700
800
900
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Quantity
Cumulative Percentage
What’s the biggest problem?
DEFINING THE PROBLEM
• Write a simple statement that defines the problem
• Use this to get your team on the same page
• Its nearly impossible to fix unclear problems
ASSEMBLING A TEAM
• A team of 3-5 is ideal• Consider folks both familiar and unfamiliar with the problem• Inquisitive team members help
CAUSE AND EFFECT CHART
Open Fire (Problem)
CAUSE AND EFFECT CHART
Open Fire
Oily Rags
Oxygen
Match
Match Strike
Ca
use
d B
y
CAUSE AND EFFECT CHART
Open Fire
Oily Rags
Oxygen
Match
Match Strike
Smoking
FireworksC
au
sed
By
Ca
use
d B
y
CAUSE AND EFFECT CHART
Open Fire
Oily Rags
Oily Bike Parts
Rags Never Cleaned
Oxygen
Match
Match Strike
Smoking
FireworksC
au
sed
By
Ca
use
d B
y
CAUSE AND EFFECT CHART
Open Fire
Oily Rags
Oily Bike Parts
Rags Never Cleaned
No Schedule
No OwnershipOxygen
Match
Match Strike
Smoking
Fireworks No Policy
Ca
use
d B
y
Ca
use
d B
y
Ca
use
d B
y
Root Cause?
IDENTIFY SOLUTIONS
Look for effective solutions that:• Prevent recurrence• Are within your control• Meet your goals• Don’t cause other problems• Don’t break the bank
CAUSE AND EFFECT CHART
Open Fire
Oily Rags
Oily Bike Parts
Rags Never Cleaned
No Schedule
No OwnershipOxygen
Match
Match Strike
Smoking
Fireworks No Policy
Ca
use
d B
y
Ca
use
d B
y
Ca
use
d B
y
Solutions?
IMPLEMENT THE BEST SOLUTIONS
Don’t implement all solutions, only the best solutions
Make one person responsible
• They don’t have to do everything
• They do have to ensure it all gets done
Assign a date for each item to be completed by
Empower your staff!
IF AT FIRST YOU DON’T SUCCEED…
Measure & Validate – this is crucial!• Did the solutions really fix your problem? Create others?• Not fixed? Run it again
Define a problem
Assemble a team
Cause & effect chart
Identify Solutions
Implement best solutions
Measure & Validate
0
100
200
300
400
500
600
700
800
900
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
How can you measure & validate?
ROOT CAUSE ANALYSIS
Define a problem
Assemble a team
Cause & effect chart
Identify Solutions
Implement best solutions
Measure & Validate
DON’T FORGET…
Celebrate success with your team!
On to the next challenge…
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