1st Edition

Root Cause Analysis A Step-By-Step Guide to Using the Right Tool at the Right Time

By Matthew A. Barsalou Copyright 2015
    154 Pages 72 B/W Illustrations
    by Productivity Press

    Although there are many books on root cause analysis (RCA), most concentrate on team actions such as brainstorming and using quality tools to discuss the failure under investigation. These may be necessary steps during RCA, but authors often fail to mention the most important member of an RCA team—the failed part.

    Root Cause Analysis: A Step-By-Step Guide to Using the Right Tool at the Right Time
    provides authoritative guidance on how to empirically investigate quality failures using scientific method in the form of cycles of plan-do-check-act (PDCA), supported by the use of quality tools.

    Focusing on the use of proven quality tools to empirically investigate issues, the book starts by describing the theoretical background behind using the scientific method and quality tools for RCA. Next, it supplies step-by-step instructions for performing RCA with the tools discussed in the first section. The book’s clear examples illustrate how to integrate PDCA with the scientific method and quality tools when investigating real-world quality failures.

    This RCA guide provides root cause investigators with a tool kit for the quick and accurate selection of the appropriate tool during a root cause investigation. It includes an appendix with a guide to tool selection based on the intended use of the tool. There is also an appendix that defines the terminology used in the book.

    After reading this book, you will understanding how to integrate the scientific method, quality tools, and statistics, in the form of exploratory data analysis, to build a picture of the actual situation under investigation that will lead you to the true root cause of an event.

    The tools and concepts presented in the text are appropriate for professionals in both the manufacturing and service industries.

    INTRODUCTION TO ROOT CAUSE ANALYSIS

    The Scientific Method and Root Cause Analysis

    The Classic Seven Quality Tools for Root Cause Analysis

    The Seven Management Tools

    Other Tools for Root Cause Analysis

    Exploratory Data Analysis and Root Cause Analysis

    Customer Complaint-Related Root Cause Analysis

    Example of a Root Cause Analysis

    ROOT CAUSE ANALYSIS QUICK REFERENCE

    Introduction to Root Cause Analysis
    Introduction
    Key Points

    The Science of Root Cause Analysis
    Hypothesis as a Basis for New Knowledge
    Key Points
    Scientific Method and Root Cause Analysis
    Key Points
    Experimentation for Root Cause Analysis
    Key Points

    The Classic Seven Quality Tools
    Introduction
    Ishikawa Diagram
    Key Points
    Check Sheet
    Check Sheet with Tally Marks
    Key Points
    Check Sheet with Graphical Representations
    Key Points
    Run Charts
    Key Points
    Histogram
    Key Points
    Pareto Chart
    Key Points
    Scatter Plot
    Key Points
    Flowchart
    Key Points

    The Seven Management Tools
    Introduction
    Matrix Diagram
    Key Points
    Activity Network Diagram
    Key Points
    Prioritization Matrix
    Key Points
    Interrelationship Diagram
    Key Points
    Tree Diagram
    Key Points
    Process Decision Tree Chart
    Key Points
    Affinity Diagram
    Key Points

    Other Quality Tools for Root Cause Analysis
    5 Why
    Key Points
    Cross Assembling
    Key Points
    Is-Is
    Not Analysis
    Key Points
    Following Lines of Evidence
    Key Points
    Parameter Diagram
    Key Points
    Boundary Diagram
    Key Points

    Exploratory Data Analysis
    Introduction
    Key Points
    Procedure
    Stem-and-Leaf Plot
    Key Points
    Box-and-Whisker Plots
    Key Points
    Multi-Vari Chart
    Key Points

    Customer Quality Issues
    Plan-Do-Check-Act for Immediate Actions
    Key Points 8D Report
    Key Points
    Corrective Actions
    Key Points

    References

    Appendix 1: Using the Tool Kit
    Appendix 2: Terminology

    Index

    Biography

    Matthew Barsalou is employed by BorgWarner Turbo Systems Engineering GmbH, where he provides engineering teams with support and training in quality-related tools and methods, including root cause analysis. He has a master of liberal studies from Fort Hays State University and a master of science in business administration and engineering from Wilhelm Büchner Hochschule. His past positions include quality/laboratory technician, quality engineer, and quality manager.

    Matthew Barsalou’s certifications include TÜV quality management representative, quality manager, quality auditor, and ISO/TS (International Organization for Standardization/Technical Specification) 16949 quality auditor as well as American Society for Quality certifications as quality technician, quality engineer, and Six Sigma Black Belt.

    He is the American Society for Quality’s Statistics Division Newsletter editor and a frequent contributor to Quality Digest, the Minitab Blog, and has published in German, American, and British quality journals.