Crash Course On Rca Training Rev 01
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TA I K I S H A P H I L I P P I N E S , I N C
OPEN CHALLENGE
QUICK RESPONSE
QUALITY MANAGEMENT
ROOT CAUSE ANALYSIS
CA / PA BASIC TOOLS
Date: Oct 09, 2009 CA/PA BASIC TOOLS Rev 01 10.08.09
TA I K I S H A P H I L I P P I N E S , I N C
OP E N C H ALLE N GE
QUICK RESPONSE
QUALITY MANAGEMENT
ROOT CAUSE ANALYSIS
CA / PA BASIC TOOLS
Date: Oct 09, 2009 CA/PA BASIC TOOLS Rev 01 10.08.09
For most of us, it's a lot easier to jump to solutions, isn't it?
2 CA/PA BASIC TOOLS Rev 01 10.08.09
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1
Objectives
Module 1: Participants will learn how to: • Create and use Pareto chart in the analysis of a problem • Implement steps for carrying out effective RCA • Select and apply tools that support RCA
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Objectives Module 2: Participants will be able to: • Define and explain the 8 – D as a Problem Solving Method
• Apply the 8 Disciplines and Concepts
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HOME PAGE
• INTRODUCTION • MODULE 1
• MODULE 2 • APPLICATION 7 CA/PA BASIC TOOLS Rev 01 10.08.09
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INTRODUCTION
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Introduction Introduction
MODULE 1
MODULE 2
Definition of Terms What it is Why use it
RCA Process How to use it
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Terms and Definition Cause (causal factor) - a condition or event that results in an effect Direct Cause - cause that directly resulted in the occurrence Contributing Cause - a cause that contributed to the occurrence, but by itself would not have caused the occurrence Root Cause - cause that, if corrected, would prevent recurrence of a non-conformity and similar occurrences
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RCA Definition
Root Cause Analysis - a process designed for use in investigating and categorizing the root causes of events
A process of tracing a Problem to its Origins
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Root Cause Analysis Process Step One: Define the Problem
Step Two: Collect Data Step Three: Identify Possible Causal Factors
Step Four: Identify the Root Cause(s)
Step Five: Recommend and Implement Solutions 12 CA/PA BASIC TOOLS Rev 01 10.08.09
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Module 1 Digging for the Root Causes
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Module 1 Table of Contents MODULE 1
MODULE 2
APPLICATION
Histograms and Pareto Chart Cause and Effect Diagram What it is How to use it Examples
Summary 14 CA/PA BASIC TOOLS Rev 01 10.08.09
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Histograms- What it is • A chart that graphically display the distribution of a set of data.
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Pareto Chart - What it is A Pareto chart allows data to be displayed as a bar chart and enables the main contributors to a problem to be highlighted. It reveals that a small number of NCNs are responsible for the bulk of quality issues, a phenomenon called the „Pareto Principle‟.
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Pareto Chart – How to create it 1. Gather facts about the problem 2. Rank the contributions to the problem in order of frequency.
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Pareto Chart – How to create it (cont’n)
3. Draw the value as a bar chart. 4. add a line showing the cumulative percentage of errors
5. Review the chart 18
6. Redefine classifications if necessary. CA/PA BASIC TOOLS Rev 01 10.08.09
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Pareto Analysis Example • Chart 1 : The chart gives summary information and starts the cumulative % count at the top of the first bar: Pareto of D3 Small Engine Card Faults
600
100
500
80
Percent
Count
400 300
60 40
200 20
100
e ec . ir d Sp lan epa v al oar c t. atp d R Remo tedh B E ted rHeed r teic itle lty itm is f itug tin ldge m epe. tF ry c to dt Fau osnfo n e M t Mthr o g Sho t ne m ble g t Mscis tiona Juo t cin atio eadE niso Csoin dTnoo moanen nsennot hoorn u Pr o n ired tM e ap t o l a g o p p p o D m c n W y ts L r yS C ntamin rin k mot e m g k om pt m C fC ldeult er s Pr e mrp Co Le L oBng Thio Cm Co CW DeJo Co Lin SoFa Oth
0
Defect
Count Percent Cum %
141 139
69
52
22
20
20
17
17
17
16
13
10
10
10
8
6
23
22
11
8
4
3
3
3
3
3
3
2
2
2
2
1
1
23
45
56
65
68
71
75
77
80
83
85
87
89
91
92
94
95
5
29
1
5
0
95 100
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Pareto Analysis Example • Example 2 : a series of Pareto charts drill down to more detail: Fault by Main Cause 100
1st level Analysis gives “Design” as main cause of failure
70 80
60
Percent
Count
50 40 30
60 40
20 20 10 0
Defect Count Percent Cum %
gn Desi
57 75.0 75.0
2nd level Analysis gives breakdown of “Design”
0
nt pone Com
er Oth
Build
13 17.1 92.1
4 5.3 97.4
2 2.6 100.0
Design Faults 100 50 80
Percent
Count
40 30 20
Defect
40 20
10 0
60
ule Mod ec t Conn
Count Percent Cum %
21 36.8 36.8
ue Torq
or s Mot
10 17.5 54.4
ule tion Mod libra t uc er Star ansd C Ca Tr A SI Cold 8 14.0 68.4
8 14.0 82.5
5 8.8 91.2
0 IOP 3 5.3 96.5
Imon 2 3.5 100.0
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Pareto Analysis Example • Example 3 : if the original Pareto is very flat, be prepared to cut the defects in a different way, here, it is 40:60 Pareto Chart for Child11 100 80
Percent
Count
200
100
60 40 20
0
Defect Count Percent Cum %
788 646 777 780 CC CC CC CC KD KD KD KD
E 10 - 47 1623 - 7274 - 81 - 78 4 782 795 64 666 40- 56 CC CC 40- 5 40KD KD
0 er s Oth
18
13
11
11
11
10
9
9
8
138
7.6 7.6
5.5 13.0
4.6 17.6
4.6 22.3
4.6 26.9
4.2 31.1
3.8 34.9
3.8 38.7
3.4 42.0
58.0 100.0
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Pareto Analysis Example How it helps Pareto Analysis is a useful tool to: •
identify and prioritize major problem areas based on frequency of occurrence;
•
separate the „vital few‟ from the „useful many‟ things to do;
•
identify major causes and effects.
The technique is often used in conjunction with Brainstorming and Cause and Effect Analysis. HINT ! The most frequent is not always the most important! Be aware of the impact of other causes on Customers or goals. 22 CA/PA BASIC TOOLS Rev 01 10.08.09
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Pareto Chart and Analysis A method for showing the distribution of quantitative data and identifying those with the greatest impact.
Process Steps Pareto
Identify the problem and the potential direct or contributing causes
Summary Pareto Charts provide a visual representation of the variables which contribute to problems or issues. Pareto Charts can be used as a prioritization tool to aid in focusing on the top issues which contribute to specific conditions. Pareto analysis is an approach which ranks the contributing factors and identifies which are the ones which have the most impact on a problem or issue. Often referred to as an approach for “separating the vital few from the trivial many”, sometimes referred to as the “80-20 rule”
Collect data about each of the potential direct or contributing causes
Construct the Pareto Chart: Causes on Horizontal Axis Frequency of events on Vertical Axis
Identify the Vital Few (those with the highest number of occurrences)
Develop Corrective Action or Improvement Action Plans for those identified as the Vital Few
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CAUSE AND EFFECT Ishikawa/Fish Bone Diagram Procedures
People
Problem
Equipment
Materials
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Cause and Effect • Cause and Effect Analysis is a tool for identifying all the possible causes associated with a particular problem Valuable for: • Focusing on causes not symptoms • Providing a picture of why an effect is happening • Establishing a sound basis for further data gathering and action • Identifying all of the areas that need to be tackled to generate a positive effect 25 CA/PA BASIC TOOLS Rev 01 10.08.09
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Cause and Effect Sources of Variation Sources of Variation is categorized as follows 1. People 2. Method 3. Machine 4. Material 5. Environment 6. Measuring System
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How to do it • 1. Identify the Problem/Issue • 2. Brainstorm 3. Draw fishbone diagram Place the effect at the head of the “fish” Include the 6 recommended categories shown below People
Method
Machine
Problem or Issue
Material
Environment
Measurement System
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How to do it (cont’n) • 4. Align Outputs with Cause Categories • 5. Allocate Causes • 6. Analyze for Root Causes • 7. Test for Reality
Tip ! The 6 categories recommended will address almost all scenarios. However, there is no one perfect set of categories. You may need to adapt to suit the issue being analyzed.
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Sources of Variation - People
People •
The activities of the workers.
•
Variations caused by skill, knowledge, competency and attitude
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Sources of Variation - Method
Method
• The methods used to produce the products. •
Variations caused by inappropriate methods or processes.
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Sources of Variation - Machine
Machine •
The equipment used to produce the products.
•
Variations caused by temperature, tool wear and vibration.
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Sources of Variation - Material
Material
• The "ingredients" of a process. •
Variations caused by materials that differ by industry, product and stage of production.
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Sources of Variation - Environment
Environment • The methods used to control the environment. • Variations caused by temperature changes, humidity etc.
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Sources of Variation – Measurement System
Measurement System • The methods and instruments used to evaluate products. • Variations caused by measuring techniques, or calibration and maintenance of the instruments.
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Cause and Effect Analysis Example
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PROBLEM SOLVING FAILURE
•
Jumping to conclusion
•
Failure to define problem
•
Failure to find the root cause
•
Weak problem solving
•
No execution of corrective action
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PROBLEM SOLVING SUCCESS -
Problem is clearly defined. Problem is accepted As an opportunity/challenge to improve True root cause is found Implemented an effective and irreversible corrective and preventive action - Problem did not re-occur
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Cause and Effect Diagram (Ishikawa)
A visual brainstorming tool used to help identify and categorize potential root causes named for Kaoru Ishikawa.
Summary The development of the cause and effect Fishbone diagram is credited to Kaoru Ishikawa, who pioneered quality management processes in the Kawasaki shipyards. The cause and effect diagram is used to explore potential causes (or inputs) that result in a single undesirable effect (UDE, or output). Causes are categorized under six headings, namely Machinery, Methods, Measurement, Manpower, Materials, and Environment. Potential causes can be arranged according to their level of importance or detail, resulting in a depiction of relationships and hierarchy of events. It is the hierarchy that creates a map that looks somewhat like fish bones, hence the name. The Ishikawa Fishbone Diagram is intended help you brainstorm and search for potential root causes or identify areas where there may be problems by questioning the existence of causes under each of the six categories.
Ishikawa Fishbone Template
Measurement Measurement
Methods Methods
Machinery Machinery
UDE
Causes, inputs, or sources of variation
Manpower Manpower
Materials Materials
Environment Environment
A UDE is an UnDesireable Effect
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Action Reflection Wait! I think I missed $$$ something It isn’t that they cannot see the solution, It’s that they can’t see the problem. 39 CA/PA BASIC TOOLS Rev 01 10.08.09
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Created by: Sid Calayag – Lead Auditor for Taikisha Phils., Inc Quality Management System
Presented by: Sid Calayag
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Pareto Chart and Analysis A method for showing the distribution of quantitative data and identifying those with the greatest impact.
Process Steps Pareto
Identify the problem and the potential direct or contributing causes
Summary Pareto Charts provide a visual representation of the variables which contribute to problems or issues. Pareto Charts can be used as a prioritization tool to aid in focusing on the top issues which contribute to specific conditions. Pareto analysis is an approach which ranks the contributing factors and identifies which are the ones which have the most impact on a problem or issue. Often referred to as an approach for “separating the vital few from the trivial many”, sometimes referred to as the “80-20 rule”
Collect data about each of the potential direct or contributing causes
Construct the Pareto Chart: Causes on Horizontal Axis Frequency of events on Vertical Axis
Identify the Vital Few (those with the highest number of occurrences)
Develop Corrective Action or Improvement Action Plans for those identified as the Vital Few
17 CA/PA BASIC TOOLS Rev 0 09.01.09
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Cause and Effect Diagram (Ishikawa)
A visual brainstorming tool used to help identify and categorize potential root causes named for Kaoru Ishikawa.
Ishikawa Fishbone Template
Summary The development of the cause and effect Fishbone diagram is credited to Kaoru Ishikawa, who pioneered quality management processes in the Kawasaki shipyards. The cause and effect diagram is used to explore potential causes (or inputs) that result in a single undesirable effect (UDE, or output). Causes are categorized under six headings, namely Machinery, Methods, Measurement, Manpower, Materials, and Environment. Potential causes can be arranged according to their level of importance or detail, resulting in a depiction of relationships and hierarchy of events. It is the hierarchy that creates a map that looks somewhat like fish bones, hence the name. The Ishikawa Fishbone Diagram is intended help you brainstorm and search for potential root causes or identify areas where there may be problems by questioning the existence of causes under each of the six categories.
Measurement Measurement
Methods Methods
Machinery Machinery
UDE
Causes, inputs, or sources of variation
Manpower Manpower
Materials Materials
Environment Environment
A UDE is an UnDesireable Effect
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NOTES
NOTES
NOTES
TAIKISHA PHILIPPINES, INC
Training Evaluation Form Date: OCT 09, 2009 Name of Attendee: _________________________ Course Title: ROOT CAUSE ANALYSIS TRAINING CRASH-COURSE Trainer: SID CALAYAG POOR
FAIR
GOOD
1.
The trainer knew the material well enough to teach this course.
2.
The trainer is well prepared.
3.
The trainer keep the class discussions focused on the training orientation content.
4.
The orientation gave me information that will help me perform my job safer.
5.
I found the training workshop is applicable in my job assignment.
6.
The trainer presented useful summaries and to be understood to me better..
7.
The trainer provided enough questions and answers opportunities.
8. 9. 10.
The trainer provided visuals that are very helpful in my training
The quality of the handout is ____________. (Poor, Fair, Good) This orientation is timely for the organization’s current situation
My comments and suggestions in this orientation/training are: __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
_______________________________
OVERALL EVALUATION: _____________
Signature
Individual Rating: Poor : 1 – 3, Fair: 4 – 7, Good: 8 – 10
Overall Rating: Poor : 10 – 30
Fair: 40 – 70 Good: 80 - 100
OPEN CHALLENGE
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QUALITY MANAGEMENT
ROOT CAUSE ANALYSIS
CA / PA BASIC TOOLS
Date: Oct 09, 2009 CA/PA BASIC TOOLS Rev 01 10.08.09
TA I K I S H A P H I L I P P I N E S , I N C
OP E N C H ALLE N GE
QUICK RESPONSE
QUALITY MANAGEMENT
ROOT CAUSE ANALYSIS
CA / PA BASIC TOOLS
Date: Oct 09, 2009 CA/PA BASIC TOOLS Rev 01 10.08.09
For most of us, it's a lot easier to jump to solutions, isn't it?
2 CA/PA BASIC TOOLS Rev 01 10.08.09
TA I K I S H A P H I L I P P I N E S , I N C
OP E N C H ALLE N GE
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1
Objectives
Module 1: Participants will learn how to: • Create and use Pareto chart in the analysis of a problem • Implement steps for carrying out effective RCA • Select and apply tools that support RCA
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Objectives Module 2: Participants will be able to: • Define and explain the 8 – D as a Problem Solving Method
• Apply the 8 Disciplines and Concepts
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2
HOME PAGE
• INTRODUCTION • MODULE 1
• MODULE 2 • APPLICATION 7 CA/PA BASIC TOOLS Rev 01 10.08.09
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INTRODUCTION
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Introduction Introduction
MODULE 1
MODULE 2
Definition of Terms What it is Why use it
RCA Process How to use it
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Terms and Definition Cause (causal factor) - a condition or event that results in an effect Direct Cause - cause that directly resulted in the occurrence Contributing Cause - a cause that contributed to the occurrence, but by itself would not have caused the occurrence Root Cause - cause that, if corrected, would prevent recurrence of a non-conformity and similar occurrences
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RCA Definition
Root Cause Analysis - a process designed for use in investigating and categorizing the root causes of events
A process of tracing a Problem to its Origins
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Root Cause Analysis Process Step One: Define the Problem
Step Two: Collect Data Step Three: Identify Possible Causal Factors
Step Four: Identify the Root Cause(s)
Step Five: Recommend and Implement Solutions 12 CA/PA BASIC TOOLS Rev 01 10.08.09
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Module 1 Digging for the Root Causes
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Module 1 Table of Contents MODULE 1
MODULE 2
APPLICATION
Histograms and Pareto Chart Cause and Effect Diagram What it is How to use it Examples
Summary 14 CA/PA BASIC TOOLS Rev 01 10.08.09
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Histograms- What it is • A chart that graphically display the distribution of a set of data.
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Pareto Chart - What it is A Pareto chart allows data to be displayed as a bar chart and enables the main contributors to a problem to be highlighted. It reveals that a small number of NCNs are responsible for the bulk of quality issues, a phenomenon called the „Pareto Principle‟.
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Pareto Chart – How to create it 1. Gather facts about the problem 2. Rank the contributions to the problem in order of frequency.
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Pareto Chart – How to create it (cont’n)
3. Draw the value as a bar chart. 4. add a line showing the cumulative percentage of errors
5. Review the chart 18
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Pareto Analysis Example • Chart 1 : The chart gives summary information and starts the cumulative % count at the top of the first bar: Pareto of D3 Small Engine Card Faults
600
100
500
80
Percent
Count
400 300
60 40
200 20
100
e ec . ir d Sp lan epa v al oar c t. atp d R Remo tedh B E ted rHeed r teic itle lty itm is f itug tin ldge m epe. tF ry c to dt Fau osnfo n e M t Mthr o g Sho t ne m ble g t Mscis tiona Juo t cin atio eadE niso Csoin dTnoo moanen nsennot hoorn u Pr o n ired tM e ap t o l a g o p p p o D m c n W y ts L r yS C ntamin rin k mot e m g k om pt m C fC ldeult er s Pr e mrp Co Le L oBng Thio Cm Co CW DeJo Co Lin SoFa Oth
0
Defect
Count Percent Cum %
141 139
69
52
22
20
20
17
17
17
16
13
10
10
10
8
6
23
22
11
8
4
3
3
3
3
3
3
2
2
2
2
1
1
23
45
56
65
68
71
75
77
80
83
85
87
89
91
92
94
95
5
29
1
5
0
95 100
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Pareto Analysis Example • Example 2 : a series of Pareto charts drill down to more detail: Fault by Main Cause 100
1st level Analysis gives “Design” as main cause of failure
70 80
60
Percent
Count
50 40 30
60 40
20 20 10 0
Defect Count Percent Cum %
gn Desi
57 75.0 75.0
2nd level Analysis gives breakdown of “Design”
0
nt pone Com
er Oth
Build
13 17.1 92.1
4 5.3 97.4
2 2.6 100.0
Design Faults 100 50 80
Percent
Count
40 30 20
Defect
40 20
10 0
60
ule Mod ec t Conn
Count Percent Cum %
21 36.8 36.8
ue Torq
or s Mot
10 17.5 54.4
ule tion Mod libra t uc er Star ansd C Ca Tr A SI Cold 8 14.0 68.4
8 14.0 82.5
5 8.8 91.2
0 IOP 3 5.3 96.5
Imon 2 3.5 100.0
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9
Pareto Analysis Example • Example 3 : if the original Pareto is very flat, be prepared to cut the defects in a different way, here, it is 40:60 Pareto Chart for Child11 100 80
Percent
Count
200
100
60 40 20
0
Defect Count Percent Cum %
788 646 777 780 CC CC CC CC KD KD KD KD
E 10 - 47 1623 - 7274 - 81 - 78 4 782 795 64 666 40- 56 CC CC 40- 5 40KD KD
0 er s Oth
18
13
11
11
11
10
9
9
8
138
7.6 7.6
5.5 13.0
4.6 17.6
4.6 22.3
4.6 26.9
4.2 31.1
3.8 34.9
3.8 38.7
3.4 42.0
58.0 100.0
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Pareto Analysis Example How it helps Pareto Analysis is a useful tool to: •
identify and prioritize major problem areas based on frequency of occurrence;
•
separate the „vital few‟ from the „useful many‟ things to do;
•
identify major causes and effects.
The technique is often used in conjunction with Brainstorming and Cause and Effect Analysis. HINT ! The most frequent is not always the most important! Be aware of the impact of other causes on Customers or goals. 22 CA/PA BASIC TOOLS Rev 01 10.08.09
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10
Pareto Chart and Analysis A method for showing the distribution of quantitative data and identifying those with the greatest impact.
Process Steps Pareto
Identify the problem and the potential direct or contributing causes
Summary Pareto Charts provide a visual representation of the variables which contribute to problems or issues. Pareto Charts can be used as a prioritization tool to aid in focusing on the top issues which contribute to specific conditions. Pareto analysis is an approach which ranks the contributing factors and identifies which are the ones which have the most impact on a problem or issue. Often referred to as an approach for “separating the vital few from the trivial many”, sometimes referred to as the “80-20 rule”
Collect data about each of the potential direct or contributing causes
Construct the Pareto Chart: Causes on Horizontal Axis Frequency of events on Vertical Axis
Identify the Vital Few (those with the highest number of occurrences)
Develop Corrective Action or Improvement Action Plans for those identified as the Vital Few
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CAUSE AND EFFECT Ishikawa/Fish Bone Diagram Procedures
People
Problem
Equipment
Materials
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Cause and Effect • Cause and Effect Analysis is a tool for identifying all the possible causes associated with a particular problem Valuable for: • Focusing on causes not symptoms • Providing a picture of why an effect is happening • Establishing a sound basis for further data gathering and action • Identifying all of the areas that need to be tackled to generate a positive effect 25 CA/PA BASIC TOOLS Rev 01 10.08.09
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Cause and Effect Sources of Variation Sources of Variation is categorized as follows 1. People 2. Method 3. Machine 4. Material 5. Environment 6. Measuring System
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12
How to do it • 1. Identify the Problem/Issue • 2. Brainstorm 3. Draw fishbone diagram Place the effect at the head of the “fish” Include the 6 recommended categories shown below People
Method
Machine
Problem or Issue
Material
Environment
Measurement System
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How to do it (cont’n) • 4. Align Outputs with Cause Categories • 5. Allocate Causes • 6. Analyze for Root Causes • 7. Test for Reality
Tip ! The 6 categories recommended will address almost all scenarios. However, there is no one perfect set of categories. You may need to adapt to suit the issue being analyzed.
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Sources of Variation - People
People •
The activities of the workers.
•
Variations caused by skill, knowledge, competency and attitude
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Sources of Variation - Method
Method
• The methods used to produce the products. •
Variations caused by inappropriate methods or processes.
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Sources of Variation - Machine
Machine •
The equipment used to produce the products.
•
Variations caused by temperature, tool wear and vibration.
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Sources of Variation - Material
Material
• The "ingredients" of a process. •
Variations caused by materials that differ by industry, product and stage of production.
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Sources of Variation - Environment
Environment • The methods used to control the environment. • Variations caused by temperature changes, humidity etc.
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Sources of Variation – Measurement System
Measurement System • The methods and instruments used to evaluate products. • Variations caused by measuring techniques, or calibration and maintenance of the instruments.
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Cause and Effect Analysis Example
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PROBLEM SOLVING FAILURE
•
Jumping to conclusion
•
Failure to define problem
•
Failure to find the root cause
•
Weak problem solving
•
No execution of corrective action
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PROBLEM SOLVING SUCCESS -
Problem is clearly defined. Problem is accepted As an opportunity/challenge to improve True root cause is found Implemented an effective and irreversible corrective and preventive action - Problem did not re-occur
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Cause and Effect Diagram (Ishikawa)
A visual brainstorming tool used to help identify and categorize potential root causes named for Kaoru Ishikawa.
Summary The development of the cause and effect Fishbone diagram is credited to Kaoru Ishikawa, who pioneered quality management processes in the Kawasaki shipyards. The cause and effect diagram is used to explore potential causes (or inputs) that result in a single undesirable effect (UDE, or output). Causes are categorized under six headings, namely Machinery, Methods, Measurement, Manpower, Materials, and Environment. Potential causes can be arranged according to their level of importance or detail, resulting in a depiction of relationships and hierarchy of events. It is the hierarchy that creates a map that looks somewhat like fish bones, hence the name. The Ishikawa Fishbone Diagram is intended help you brainstorm and search for potential root causes or identify areas where there may be problems by questioning the existence of causes under each of the six categories.
Ishikawa Fishbone Template
Measurement Measurement
Methods Methods
Machinery Machinery
UDE
Causes, inputs, or sources of variation
Manpower Manpower
Materials Materials
Environment Environment
A UDE is an UnDesireable Effect
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Action Reflection Wait! I think I missed $$$ something It isn’t that they cannot see the solution, It’s that they can’t see the problem. 39 CA/PA BASIC TOOLS Rev 01 10.08.09
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Created by: Sid Calayag – Lead Auditor for Taikisha Phils., Inc Quality Management System
Presented by: Sid Calayag
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19
Pareto Chart and Analysis A method for showing the distribution of quantitative data and identifying those with the greatest impact.
Process Steps Pareto
Identify the problem and the potential direct or contributing causes
Summary Pareto Charts provide a visual representation of the variables which contribute to problems or issues. Pareto Charts can be used as a prioritization tool to aid in focusing on the top issues which contribute to specific conditions. Pareto analysis is an approach which ranks the contributing factors and identifies which are the ones which have the most impact on a problem or issue. Often referred to as an approach for “separating the vital few from the trivial many”, sometimes referred to as the “80-20 rule”
Collect data about each of the potential direct or contributing causes
Construct the Pareto Chart: Causes on Horizontal Axis Frequency of events on Vertical Axis
Identify the Vital Few (those with the highest number of occurrences)
Develop Corrective Action or Improvement Action Plans for those identified as the Vital Few
17 CA/PA BASIC TOOLS Rev 0 09.01.09
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Cause and Effect Diagram (Ishikawa)
A visual brainstorming tool used to help identify and categorize potential root causes named for Kaoru Ishikawa.
Ishikawa Fishbone Template
Summary The development of the cause and effect Fishbone diagram is credited to Kaoru Ishikawa, who pioneered quality management processes in the Kawasaki shipyards. The cause and effect diagram is used to explore potential causes (or inputs) that result in a single undesirable effect (UDE, or output). Causes are categorized under six headings, namely Machinery, Methods, Measurement, Manpower, Materials, and Environment. Potential causes can be arranged according to their level of importance or detail, resulting in a depiction of relationships and hierarchy of events. It is the hierarchy that creates a map that looks somewhat like fish bones, hence the name. The Ishikawa Fishbone Diagram is intended help you brainstorm and search for potential root causes or identify areas where there may be problems by questioning the existence of causes under each of the six categories.
Measurement Measurement
Methods Methods
Machinery Machinery
UDE
Causes, inputs, or sources of variation
Manpower Manpower
Materials Materials
Environment Environment
A UDE is an UnDesireable Effect
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NOTES
NOTES
NOTES
TAIKISHA PHILIPPINES, INC
Training Evaluation Form Date: OCT 09, 2009 Name of Attendee: _________________________ Course Title: ROOT CAUSE ANALYSIS TRAINING CRASH-COURSE Trainer: SID CALAYAG POOR
FAIR
GOOD
1.
The trainer knew the material well enough to teach this course.
2.
The trainer is well prepared.
3.
The trainer keep the class discussions focused on the training orientation content.
4.
The orientation gave me information that will help me perform my job safer.
5.
I found the training workshop is applicable in my job assignment.
6.
The trainer presented useful summaries and to be understood to me better..
7.
The trainer provided enough questions and answers opportunities.
8. 9. 10.
The trainer provided visuals that are very helpful in my training
The quality of the handout is ____________. (Poor, Fair, Good) This orientation is timely for the organization’s current situation
My comments and suggestions in this orientation/training are: __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________
_______________________________
OVERALL EVALUATION: _____________
Signature
Individual Rating: Poor : 1 – 3, Fair: 4 – 7, Good: 8 – 10
Overall Rating: Poor : 10 – 30
Fair: 40 – 70 Good: 80 - 100
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