PEPMACO MANUFACTURING CORPORATION
ROOT CAUSE ANALYSIS
Cause-and-Effect
Diagram
December Improve people's skills and capability to
1, 2022 analyze complaints occurrence
Why-Why
Analysis
1. Understand the importance of
identifying root cause in
probelm solving
Learning
2. Describe how to apply common
Root Cause Analysis tools such
as 5 Whys & Cause and Effect
Diagram to identify as root
objectives
cause
3. Learn how to prioritize root
causes with a Pareto Chart
4. Gain awareness of the
pitfalls in root cause analysis
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Agenda Introduction
Key Concepts and Principles
of RCA
Overview of Problem Solving
Process
RCA using 5 Whys, Cause and
Effect Diagram and Pareto
Chart
What is Root cause
analysis?
Root Cause Analysis (RCA) is a technique that helps
guide people to discover and understand the initiating
cause/s of a problem, with the goal of determining
missing or inadequately applied controls that will
prevent recurrence.
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symptoms
HIGH
Results or outcome of the problem
What you see as the problem
(Obvious)
problem Understanding Root causes
Gap from goal or standard
Root causes
System below the surface, bringing
about the problem
LOW
(Not obvious)
Systematic Thinking Standard - what should be happening
1
approach
Prevention of recurrence
2
GAP = PROBLEM
3 Pareto Principle
Continuous Improvement Current Situation- what is actually happening
4
Problem is ....
principles of Root Cause
Analysis A problem is a deviation from a standard, i.e., a difference
between what should be happening and what is actually
happening
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Problem Solving Funnel Back to Agenda Page
Breakdown
Grasp the Situation The Three
Actual vs. Standard Realities
Actual vs. Ideal
principles
5 Whys Analysis
Root Cause
COUNTERMEASURE
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The Three Realities
principles
(Sangen Shugi)
Actual Place GENBA 現場
Actual Part/Item GENBUTSU 現物
Actual Situation GENJITSU 現実
What is Root Cause?
1 Solutions must deal with root cause, not symptoms
An event, condition or state that when
removed, remediated or controlled,
prevents recurrence of an undesirable
behavior.
2 Ask "Why?" five times to get to the root cause
3 Use the Cause-and-Effect Diagram
Dealing with Root Cause
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"Intellectuals solve the problems.
Geniuses prevents them."
Albert Einstein
What is 5 Why
Analysis?
a method used for finding out the root cause of a
problem or symptom. In this method a series of why
questions are asked about the problem. And finally we
will reach the root cause of the problem.
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Benefits of 5 Whys
1. Improve analytical thinking
2. Improve the knowledge of the 3. Develop the consciousness
function, structure and about the abnormalities 5. Develop the way of
mechanism of the causing troubles in the prevention of occurrence.
equipment/process. workplace.
4. Aim to level up the ability of
the people.
Key Points of 5 Why Back to Agenda Page
Verify facts using three Try to make your answer
realities principle more precise
Connect the why's in a chain Look for the cause step by step.
of logic Don't jump to conclusion.
Should end up the investigation where the Never consider the root cause as "human
causes can be prevented error" or "worker inattention"
Use the 'hence' logic to check Ask "why" until the root cause
the chain of logic is is determined
continuous
No assumption, No guesses
5 Why analysis Problem: Material was delivered not on time
sample
Why 1: Why material was not reached on time? Ans. 1: Because the material was dispatched late
Ans. 2: Because the material was not ready on
Why 2: Why material was dispatched late?
time
Why 3: Why material was not ready on time? Ans. 3: Material specification reached late
Ans. 4: Material specification was not sent with
Why 4: Why specification reached late?
P.O.
Ans. 5: Purchase person missed to send it
Why 5: Why specification was not sent with P.O.?
together
Why 6: Why the person missed to send it Ans. 6: Incomplete training or induction process of
together? new employee
Team Brainstorm Back to Agenda Page
using 5 Why analysis
Create a group and discuss a specific Brainstorm ideas to solve the prblem
problem that you are currently facing. using why why analysis and provide
countermeasures to prevent it
What is Cause and
effect diagram?
A cause-effect diagram is a visual tool used to logically
organize possible causes for a specific problem or effect
by graphically displaying them in increasing detail,
suggesting causal relationships among theories.
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Benefits of C-E
Diagram
1. Display relationships clearly and
logically
2. Show all causes simultaneously
3. Facilitate brainstorming
4. Stimulate problem solving
5. Help maintain team focus
Key Points of C-E Diagram Back to Agenda Page
Improve understanding A cause-effect diagram cannot
relationship of cause and effects identify a root cause; it presents
graphically the many causes that
Can check possible causes in 4M
might contribute to the
(Man, Machine, Method, Material)
observed effect.
It encourages innovative thinking and still
keeps the team on track in an orderly way.
More detail is always better.
Use the 4W 1 H (What, When,
Why, Where, How)
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Effect
Define clearly the effect or symptom
for which the causes must be
identified.
Major Causes
Mostly used the 4M representation Understanding Fishbone
(Man-Machine-Method-Material)
Diagram
causes
Hypothetical or possible causes
under the major cause
C-E Diagram sample
MATERIAL METHOD No checking of
final condition of
Supplier's
sachets before
Defect-with
casing
hole in the
received rolls
One sachet of Fabric
Conditioner have
leakage
Weak Sealing
of machine No awareness for
the possibility of
leakage during
MACHINE MAN process
Team Brainstorm Back to Agenda Page
using Cause-effect diagram
Create a group and discuss a specific Brainstorm ideas to solve the prblem
problem that you are currently facing. using cause and effect diagram and
provide countermeasures to prevent it
Root cause prioritization
What is Pareto Chart?
A Pareto chart is a bar graph or the combination of bar
and line graphs. The purpose of using this chart is to
represent a set of data in a bar graph chart. The values
are expressed from the longest bar to the shortest bar in
the graph.
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Collect your data sets based on
the current problem
Make sure your data is in
quantitative measures
Input your data in one excel
Sort your data sets in descending order
how to use pareto chart
Compute your accumulated
percentage by (summation of
accumulated scores per item then
divide in the totality of items quantity)
Team Brainstorm Back to Agenda Page
using Pareto Chart
Create a pareto chart using the given data
Share your thoughts Back to Agenda Page
Share what you learn today!
Thank you!
Melissa Lazado
PROCESS AND SYSTEM AUDIT OFFICER
