What is Root Cause Analysis in Manufacturing?
Root Cause Analysis (RCA) is a process of identifying the actual cause of the problems and finding solutions to improve the product, process, and service. It is a systematic process that allows organizations to address issues effectively and prevent their occurrence in the future. Regardless of industry, RCA plays a vital role in improving processes, ensuring quality, and reducing operational disruptions.
Solutions like Acumatica ERP with an integrated Quality Management Suite provide manufacturers with comprehensive quality control solution. The solution allows the users to document non-conformances, RCA findings, and implement corrective and preventive actions. In this blog post, we will explore types of root cause analysis, how to do root cause analysis, RCA methods, examples of root cause analysis, and its benefits.
Types of Root Cause Analysis
Root cause analysis is classified into the below five categories:
- Safety-Based RCA: Risks and hazards that can cause accidents and injuries in the manufacturing unit.
- Production-Based RCA: Manufacturing defects that can affect productivity and quality.
- Process-Based RCA: It includes identifying processes in the manufacturing unit that can cause inefficiencies and disruptions.
- System-Based RCA: Deviations in systems that cause system failures and affect the overall system performance.
- Failure-Based RCA: Mechanical failures that lead to equipment malfunction.
How To Conduct Root Cause Analysis?
- Identify the Problem
The first step is to identify the areas of problem and detect the issues. Key to define a clear problem statement to analyze the root cause. Problems can be machine malfunction causing production delays, products that do not meet quality standards, or supply chain compliance. - Collect Data
Gather the data related to the problem. The data includes records, documents, equipment, data related to processes, and personnel involved. Prepare the list of factors and series of events or situations that led to the problem. Collect any information that is helpful to identify the root cause of the issue. - Determine Root Causes
At this stage, examine and use the root cause analysis methods or tools like 5 whys and DMAIC, which are explained below. Determine the root cause based on the list of factors prepared. Assess the causes and track the factors to identify and determine the actual root cause of the issue. - Develop and Implement The Solutions
After identifying the root cause, develop a strategy and implement a solution to eliminate the root cause. Determine the preventive actions to prevent them from recurring in the future. The solution includes a change of processes, training of personnel, updating SOPs (statement of procedures), and more. - Verify the Effectiveness
After implementing the solutions, it’s vital to verify and monitor the effectiveness of the solutions. It helps to ensure the solution is implemented correctly and the problem has been eliminated effectively. The verification stage allows manufacturers to ensure the issue is addressed successfully and encourages continuous improvement in a company. - Communicate and Document
Lastly, document the findings and communicate them as needed to help avoid the occurrence in the future. This ensures transparency, accountability, and long-term benefits for the organization.
Common Methods and Examples Of Root Cause Analysis
Manufacturers must use effective techniques and tools to conduct root cause analysis that will lead them to the actual root cause of the issue and enable them to collect data and take action effectively. Explore root cause analysis methods that are used commonly and learn with root cause analysis examples:
5 Why’s
This is the most common methodology used to perform root cause analysis. It includes simply asking 5 Why questions.
Example: Machine failure is a problem.
- First Why: Why the machine failed? – It failed due to improper installation
- Second Why: Why was the machine not installed properly? – Due to lack of training
- Third Why: Why is the training not given on new machine installation? – Missed the training on the recent installation
- Fourth Why: Why the training was missed? – Due to improper SOPs
- Fifth Why: Why SOPs are not updated? – Updated training SOP record was missing
The root cause identified is that the machine failed due to the missing SOP record.
Change Analysis
Change analysis is used when there is a significant change in the performance of process, equipment, systems, or any condition. Change analysis contributes to effective quality management efforts by identifying the cause of changes and comparing the performance before/after the problem.
Example: A pharmaceutical manufacturing company identifies batch failure as it did not meet quality standards. Quality failed after the installation of the new filtration system, and the investigation team came across the fact that the filtration pore size was different. It’s identified that a change in filtration pore size is a cause of batch failure.
DMAIC (Define, Measure, Analyze, Improve, Control)
DMAIC stands for Define, Measure, Analyze, Improve, Control used in the company’s Six Sigma strategies to improve the capability of business processes. Manufacturing companies use it to improve manufacturing quality by identifying the root causes of the deviations.
Example of DMAIC root cause analysis method:
- Define: The production team experienced a machine breakdown.
- Measure: Machine breakdown is noticed twice a month.
- Analyze: The team analyzes machine breakdown happened due to irregular maintenance
- Improve: Implement ad-hoc quality control checks and update SOPs for regular machine maintenance
- Control: Monitor the process regularly to ensure SOP and quality control checks are implemented with an 80% reduction in downtime.
Why is Root Cause Analysis Important?
RCA in manufacturing has several benefits:
- It helps eliminate deviations and avoid the recurrence of similar issues in the future.
- Manufacturers can promptly take action with reference to previous records of issues/defects.
- It enables manufacturing companies to drive continuous improvement by consistently improving the business processes.
- Root cause analysis helps to save costs by identifying the cause of the issue and resolving them on time, avoiding delays in production and manufacturing operations.
Conclusion
Root cause analysis is vital for every manufacturing company looking to optimize its quality management and streamline the manufacturing process. Document the root cause analysis findings and actions taken with Acumatica’s Quality Management Suite. Perform quality control tests effectively to ensure the product meets specifications and drive continuous improvement.
Contact us or your Acumatica partner to learn more.
