For ease of understanding Root Cause Analysis will be addressed with the acronym RCA.
Section: Root Cause Analysis
Root Cause Analysis (RCA) is a method used to identify the underlying reasons for problems or incidents in order to prevent them from happening again. It involves systematically examining what happened, why it happened, and how to fix the root cause rather than just addressing the symptoms. This process can help organizations improve their operations, quality, and safety by ensuring that issues are resolved at their source.
Example Anchors
For example, a company notices that a significant number of products are being produced with defects. Through RCA, they might discover that the defects are due to a specific machine malfunctioning. Further investigation reveals that the machine is malfunctioning because it hasn't been maintained properly. The root cause is identified as inadequate maintenance schedules, and the solution could be to implement a more rigorous maintenance program and train staff on proper machine upkeep, thus preventing future defects.
Section: How to use Root Cause Analysis
Check out the Video Guide for a step-by-step walkthrough and detailed insights.
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Step 1
Add the Root Cause Analysis section from the available list to the required phase.
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Step 2
Expand the section by clicking anywhere in the section field, or on the arrow on the right side.
The arrow can also be used to collapse the section.
There would be various fields available in the RCA section to add information about the analysis of a cause.
The table below shows the options available in all the fields:
Useful Facts!
The process of adding information to RCA uses cascading forms. The options in the next field will depend upon the selection in the previous field.
Form Field Options |
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Field 1 | Field 2 | Field 3 | Field 4 | Field 5 |
Rootcause Category | Countermeasure | Pillar Associated to Countermeasure | Rootcause | Sub-Rootcasue Category |
Insufficient Strength | Design Weakness | Focused Improvement | Design Review | Design Weakness Step 3 EEM |
Error at the stage of assembly of the machine in Supplier’s house step 4 EEM |
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Error by Supplier at the stage of installation/programming/adjustment of equipment in our plant Step 5 EEM |
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External Factor | Inform Supplier Department | External Factor |
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Spare Parts Incorrectly Produced (Out of Specification) |
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Increased Stress | External Factor | Focused Improvement | Inform Supplier Department | External Factor |
Spare Parts Incorrectly Produced (Out of Specification) |
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Insufficient Skills | People Development | ________ | Operator’s Setup | Human Error |
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Operator’s Setup | Lack of Knowledge |
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Skilled Trade’s | Human Error |
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Skilled Trade’s | Lack of Knowledge |
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Insufficient Maintenance | Professional Maintenance | PM Calender Review | PM Condition Based Maintenance not complete |
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PM Planned Maintenance event not complete |
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PM Procedure Change (update inspection frequency) |
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PM Procedure Change (update replacement frequency) |
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Operating Conditions Not Maintained | People Development | OPL for Operator or Maintenance | Failure to follow current operating condition. |
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Basic Conditions Not Maintained | Autonomous Maintenance | AM Standard / AM Calender Review | AM Cleaning |
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AM Daily Maintenance Not Performed |
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AM Inspecting |
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AM Lubricating |
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AM Fastening |
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Deterioration | External Factor | Focused Improvement | Inform Supplier Department | External Factor |
Spare Parts Incorrectly Produced (Out of Specification) |
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Design Weakness | Focused Improvement | Design Review | Design Weakness Step 3 EEM |
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Error at the stage of assembly of the machine in Supplier’s house step 4 EEM |
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Error by Supplier at the stage of installation/programming/adjustment of equipment in our plant Step 5 EEM |
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Insufficient Skills | People Development | OPL for Operator or Maintenance | Operator’s Setup | Human Error |
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Operator’s Setup | Lack of Knowledge |
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Skilled Trade’s | Human Error |
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Skilled Trade’s | Lack of Knowledge |
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Insufficient Maintenance | Professional Maintenance | PM Calender Review | PM Condition Based Maintenance Not Complete |
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PM Planned Maintenance Doesn’t Exist |
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PM Planned Maintenance event not complete |
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PM Procedure Change (update inspection frequency) |
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PM Procedure Change (update replacement frequency) |
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Operating Conditions Not Maintained | People Development | OPL for Operator or Maintenance | Failure to follow current operating condition. |
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Basic Conditions Not Maintained | Autonomous Maintenance | AM Standard / AM Calender Review | AM Cleaning |
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AM Daily Maintenance Not Performed |
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AM Inspecting |
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AM Lubricating |
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AM Fastening |
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Enter the information as required for the issue of the kaizen.
Step 3
Once you have entered the information, Save button will become active and you can click on it to save the information.
The information will now be applied to the Plan Phase via RCA Section!
Collapse the section when you are finished!
Congratulations! We have successfully learned about the Rootcause Analysis Section inside Kaizen!
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Let’s move ahead with the Tool phase section!