Learn how to turn manufacturing failures into opportunities for process improvement and team growth with effective analysis techniques.

I have seen far too many investigations stop early, only asking “why” until they get to the point that someone did something wrong - either through omission or improper action. Good investigations should always continue at least one step deeper to identify what about the applicable process(es) caused the observed improper human behavior. In this case, the identified root cause and subsequent actions become more about improving the process(es), versus blaming people and retraining them to the same flawed system. In fact, training alone is never a sustainable solution. Always focus on “fact finding” over “fault finding” to ensure your solutions are effective and sustainable.

Last updated on Jul 31, 2024

Here's how you can effectively analyze and learn from failure in manufacturing operations.

Understanding failure in your manufacturing operations is not just about identifying what went wrong, but also about learning from the missteps to improve processes and prevent future issues. It's a critical aspect of maintaining a competitive edge and ensuring the quality of your products. When a failure occurs, it's natural to feel disheartened, but the key is to transform that setback into a stepping stone for success. By analyzing failures effectively, you can uncover the root causes, implement corrective actions, and foster a culture of continuous improvement. Remember, every failure is an opportunity to learn and grow stronger in your manufacturing journey.

1 Root Cause

When dealing with failure, it's essential to dig deep and identify the root cause. This means going beyond the symptoms and understanding the underlying issues that led to the problem. Techniques like the "5 Whys" can be helpful, where you ask "why" multiple times until you reach the fundamental cause. By pinpointing the root cause, you can develop targeted solutions that address the actual problem rather than just its manifestations. This approach prevents the recurrence of the same issue and strengthens your manufacturing process.

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Scott Long

Quality / Compliance Professional
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I have seen far too many investigations stop early, only asking “why” until they get to the point that someone did something wrong - either through omission or improper action. Good investigations should always continue at least one step deeper to identify what about the applicable process(es) caused the observed improper human behavior. In this case, the identified root cause and subsequent actions become more about improving the process(es), versus blaming people and retraining them to the same flawed system. In fact, training alone is never a sustainable solution. Always focus on “fact finding” over “fault finding” to ensure your solutions are effective and sustainable.

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Svyatoslav Tsypin

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Failure analysis in manufacturing operations requires a comprehensive approach that includes Six Sigma and continuous improvement methods. It is important to implement a real-time deviation tracking system using sensors and IoT technologies to promptly identify and document failures. Statistical analysis of production process data using regression models and machine learning methods helps to identify hidden patterns and predictors of failures. Feedback from operators and the use of the "five whys" technique helps to identify root causes, not superficial symptoms. Implementation of digital twins of production systems allows you to simulate failure scenarios and test corrective measures without stopping real production.

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Jamal Jauher

Technical Consultant
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To effectively analyze and learn from failure in manufacturing operations: 1. Acknowledge and accept failure: Recognize and accept that failure has occurred. 2. Gather data and facts: Collect information about the failure. 3. Identify root causes: Use tools like Fishbone diagrams or 5 Whys. 4. Analyze the failure: Determine what went wrong and why. 5. Document the failure: Record the failure and analysis. 6. Share knowledge: Communicate findings to relevant teams and stakeholders. 7. Develop corrective actions: Create a plan to prevent future failures. 8. Implement changes: Put corrective actions in place. 9. Monitor and evaluate: Track the effectiveness of changes. 10. Continuously improve: Refine processes and procedures.

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Gerome Cristopher Refre

Process Engineer at ST microelectronics MT
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You can also use other techniques to know the rootcause of the problems like Ishikawa Diagram and perform simulation and validation based from the 5M's and 1E that you will have on the diagram

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2 Data Analysis

Data is your ally in learning from failure. Collecting and analyzing data from your operations can reveal patterns and correlations that might not be obvious at first glance. Use statistical tools and software to crunch numbers and visualize data, making it easier to spot trends. Look for outliers or deviations from the norm that could indicate a problem. By relying on data, you can make informed decisions and take a more scientific approach to problem-solving in your manufacturing operations.

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Gerome Cristopher Refre

Process Engineer at ST microelectronics MT
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You can use different tools to analyze your data that will help you more in the issue such as SPC, Pareto Diagram, Process Commonality, etc.

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3 Team Feedback

Your team is one of your most valuable resources when analyzing failures. They have hands-on experience with the manufacturing processes and might have insights that data alone can't provide. Encourage an open dialogue where team members feel comfortable sharing their observations and suggestions. This collaborative approach fosters a sense of ownership and engagement, which is crucial for implementing effective solutions and improving operations as a whole.

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4 Process Review

Regularly reviewing your manufacturing processes is vital for identifying potential areas of failure before they occur. Conduct thorough audits and simulations to test the robustness of your processes. This proactive stance allows you to make adjustments in a controlled environment, minimizing the impact of potential failures. Continuous process review leads to incremental improvements, which cumulatively can have a significant positive impact on your manufacturing operations.

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5 Action Plan

After analyzing the failure and identifying its causes, it's time to create an action plan. This plan should outline the steps needed to correct the issue, prevent it from happening again, and improve the overall process. Assign responsibilities and set deadlines to ensure accountability. Your action plan should be a living document, regularly reviewed and updated as you gain new insights and as your manufacturing operations evolve.

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Gerome Cristopher Refre

Process Engineer at ST microelectronics MT
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After identifying the rootcause, this time you need to implement an action that will solve the issue. Its better if the action will be a pokayoke solution to prevent the re occurence of the issue. You should have detection action plan and and systemic action plan. In addition, it should be documented in the FMEA, OCAP, Work Instructions if applicable

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6 Culture Shift

Lastly, cultivating a culture that views failure as a learning opportunity is crucial. Encourage your team to view mistakes not as setbacks but as chances to innovate and improve. This mindset shift can lead to a more resilient operation where employees are proactive in identifying and solving problems. A positive culture around failure can transform your manufacturing operations, leading to higher quality products, increased efficiency, and a more engaged workforce.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Here's how you can effectively analyze and learn from failure in manufacturing operations.

1

2

3

4

5

6

7

1 Root Cause

2 Data Analysis

3 Team Feedback

4 Process Review

5 Action Plan

6 Culture Shift

7 Here’s what else to consider

Manufacturing Operations

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Here's how you can effectively analyze and learn from failure in manufacturing operations.

1

2

3

4

5

6

7

1 Root Cause

2 Data Analysis

3 Team Feedback

4 Process Review

5 Action Plan

6 Culture Shift

7 Here’s what else to consider

Manufacturing Operations

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