How can you improve product reliability with root cause analysis?

The most critical part of root cause analysis is finding the contributing factors or actual root cause(s). This is still a big challenge despite the plethora of raw data and tools at the disposal of managers, but the old-school way of Genchi Gembutsu is still the best way. You go to the source of the problem, draw a circle, and observe the process to understand the real reasons. Many professionals find it non-value-adding to spend time on the process maybe it is not easy to figure out the problem. I believe in solving problems by understanding the business process and observing it without any distraction before drilling deep down into the data and using tools such as the 5 Whys, Ishikawa diagram, and big datasets.

⏭️ Product Reliability is - How many percentage products servive at the end of defined life, for defined function & for defined working conditions. ➡️ More the product failure rate, lesser the Reliability. ➡️ Root Cuase Analysis (RCA) helps to find root causes of failures & help us to plan corrective + preventive actions to tackle them. ➡️ In turn, it helps us to correct & avoid failures in the product. It eventually enhances Product Reliability. ➡️ Without knowing root causes of failure, we end up taking superficial actions which may not solve failures in long term. ➡️ RCA methods like Why-Why Analysis, Ishikawa Diagram, Fault Tree Analysis, Parametric Diagram, Affinity Diagram & Brainstorming help us to analyse failures effectively.

RCA is a systematic problem-solving approach employed in diverse settings, including plant engineering projects. It entails a methodical series of inquiries aimed at uncovering the underlying, fundamental causes of a problem, as opposed to merely addressing its surface-level triggers. RCA can be effectively utilized to investigate and mitigate issues spanning product defects, process errors, safety incidents, and customer complaints. The objective of RCA extends beyond resolving the immediate problem at hand; it strives to establish preventive measures to avert its recurrence. RCA enables organizations to engage in a comprehensive examination of issues, facilitating the implementation of enduring solutions rather than temporary fixes.

There is a base formula for RCA. it is called the "5 why's Questionnaire." an example might be as follows: The product a ballon had a hole in it at the QC line. #1Why= How did this happen? It snagged on the conveyor. #2Why= How did it snag on the conveyor? The conveyor side edge was sharp. #3Why= Why was th conveyor edge sharp? actually the baloons travleing the conveyor are not to be piled that high. #4Why= Why are the ballons stacked to high? The proximity switch which controls the amount of ballons dropped on the conveyor in flow has failed. RCA actually before #5Why is answered QC has a hole in a baloon because the prximity switch failed and needs replaced. I use this and it elliminates any preconceived theories saving time.

In my five years at Toyota and Mitsubishi, I've seen Root Cause Analysis (RCA) as a pivotal problem-solving method. RCA systematically identifies the root causes behind issues, going beyond surface-level symptoms to prevent recurrence. It's deeply integrated into quality management and improvement processes, using techniques like the "5 Whys" and fishbone diagrams. This approach enhances product reliability, quality, and operational efficiency, leading to increased customer satisfaction and loyalty.

One thing I found helpful is a collaborative approach or team work in RCAs. Manufacturing of off-spec production can be quiet costly and result customer dissatisfaction and warantee claims e.t.c but this can be avoided by engaging a team of stakeholders from relevant department to form a kaizen/ DMAIC/ A3/ 8D) team focussed on Ongoing Problem solving by finding root causes using QC tools such 5 why's, cause and effect, checksheets e.t.c & implementing suitable corrective action. #PDCA #Ongoing

RCA is crucial for product reliability because it helps identify and address the underlying causes of issues or failures. By delving beyond surface-level symptoms, it enables organizations to pinpoint the root causes of problems in their products or processes. This allows for targeted corrective actions to prevent recurrence, ultimately leading to more reliable products. RCA is a proactive approach that helps organizations continuously improve and refine their processes, ensuring that products are built with a focus on quality and dependability. This, in turn, enhances customer satisfaction, fosters brand loyalty, and reduces the costs associated with product defects and failures.

RCA is necassary for correct & acurate resolution to a given problem. It is paramount the the RCA is documented properly and filed properly. It is certain that future problems will be resolved in the same processes in the future. The problem can then be reviewed if it reoccurs (it shouldn't but may) can be reviewed if a simular problem occurs, can be reviewed if the same problem in a different portion of the process reoccurs. Which in all cases will save time. With the use of computers these days it is fairly easy to files in such a manner that can then be searched by the problemm the RCA, the portion of the process, and/or the task or function called for in the process. Then after history data is compiled IS an exact science.

The five WHY's formula is best from my experiences in repair/resolution of machinery and process. there ARE other means of RCA. Starting at the beginning is always a good rule, finishing the entire flow of the troubleshooting process. Even thought you may have resolved the initial problem we need to finish the entire flow and function to see that what we percieve is a correction or resolution didn't in fact cause another unconsidered issue on the tail end of the process.

To conduct a Root Cause Analysis (RCA), begin by defining the problem clearly. Assemble a diverse team with relevant expertise, collect data related to the issue, and identify immediate causes. Employ the "5 Whys" technique, repeatedly asking "Why?" to delve deeper into the causes until reaching the root cause. Document findings and prioritize actions to address the root cause. Implement corrective measures, monitor results, and make necessary adjustments to prevent recurrence.

Root Cause Analysis (RCA) offers numerous benefits. It helps organizations uncover the underlying causes of problems or failures, allowing for targeted corrective actions. By addressing root causes, RCA enhances product reliability, quality, and safety, reducing the likelihood of recurring issues and minimizing associated costs. RCA also fosters a culture of continuous improvement, encouraging teams to learn from past mistakes and prevent future ones. Moreover, it can lead to increased customer satisfaction, improved brand reputation, and higher efficiency in processes. Overall, RCA is a proactive approach that not only resolves current issues but also prevents future ones, driving organizational growth and success.

Save time and Time is money in any business. Also any worker is only as good as their tools. It has Been my experience that this tool for finding RCA works. I rely on it.

RCA in engineering helps fix problems at the root, making products better and saving time and money. It also makes customers happier and gives companies an edge. It's like finding the main cause of a problem and making sure it doesn't happen again!

Convincing the management teams at times. They are sometime only hearing of the issue not about the issue. This is another reason for accurate and time/date stamped repair and correction. I do our documentaion in time and materials. In other words the sum of the documentation equals how much it cost to resolve. once i have their ear with a dollar amount I can then bridge the gap of communication to real time problems on the floor to my soupervisor and or managers.

Conducting Root Cause Analysis (RCA) presents challenges in accurately pinpointing root causes, acquiring comprehensive data, assembling capable teams, and addressing resistance to corrective actions. Nevertheless, the substantial benefits of preventing recurring issues and enhancing processes make RCA a valuable tool for organizations.

It's a challenge to continually believe that there is a cause for everything we investigate during RCA. Things don't just happen, they happen for a reason that occured in the past. Believe it and continue trying, RCA techniques will get you there

I've always use a system description that way I know all the aspects of the system or process. By doing so I can eliminate causes by knowing what to check. After elimination of the system that is not causing the failure I'm narrow down the causes. Eventually I will find it through data or mechanical or process up to human interaction in that system. Most of the time I have narrowed it down to most human interaction in the system, but not always