The Root Cause Analysis section lets you record the underlying cause of the problem a Kaizen addresses. In this article, Root Cause Analysis is shortened to RCA.
What Root Cause Analysis is
Root Cause Analysis (RCA) is a method for identifying the underlying reasons for a problem or incident so that it doesn't happen again.
You systematically examine what happened, why it happened and how to fix the root cause, rather than only addressing the symptoms. This helps organizations improve operations, quality and safety by resolving issues at their source.
Example: a company notices that many products are produced with defects. Through RCA, they discover that the defects come from a specific machine that is malfunctioning. Further investigation shows the machine hasn't been maintained properly.
The root cause is an inadequate maintenance schedule. The solution is a more rigorous maintenance program and training for staff on machine upkeep, which prevents future defects.
Use the Root Cause Analysis section
1. Add the Root Cause Analysis section from the available list to the required phase. See Add or remove sections from Kaizen phases.
2. Expand the section by clicking anywhere in the section field, or on the arrow on the right side. You can also use the arrow to collapse the section.
The RCA section has several fields for recording your analysis of the cause.
Note: the RCA fields are cascading. The options in each field depend on what you selected in the previous field. You start by choosing the Root Cause Category.
The table below shows the options available for each root cause category. The middle column shows the selections that follow in order, and the last column lists the options in the final field.
Root Cause Category | Next selections | Options in the final field |
Insufficient Strength | Design Weakness → Focused Improvement → Design Review |
|
Insufficient Strength | External Factor → Inform Supplier Department |
|
Increased Stress | External Factor → Focused Improvement → Inform Supplier Department |
|
Increased Stress | Insufficient Skills → People Development → OPL for Operator or Maintenance |
|
Increased Stress | Insufficient Maintenance → Professional Maintenance → PM Calendar Review |
|
Increased Stress | Operating Conditions Not Maintained → People Development → OPL for Operator or Maintenance |
|
Increased Stress | Basic Conditions Not Maintained → Autonomous Maintenance → AM Standard / AM Calendar Review |
|
Deterioration | External Factor → Focused Improvement → Inform Supplier Department |
|
Deterioration | Design Weakness → Focused Improvement → Design Review |
|
Deterioration | Insufficient Skills → People Development → OPL for Operator or Maintenance |
|
Deterioration | Insufficient Maintenance → Professional Maintenance → PM Calendar Review |
|
Deterioration | Operating Conditions Not Maintained → People Development → OPL for Operator or Maintenance |
|
Deterioration | Basic Conditions Not Maintained → Autonomous Maintenance → AM Standard / AM Calendar Review |
|
3. Enter the information that applies to the Kaizen's issue.
4. Click Save. The Save button becomes active after you enter the information.
5. Collapse the section when you finish. The analysis is saved to the RCA section of the phase.
Related features
RCA Agent: from the Kaizen project toolbar, click RCA Agent → Run RCA Analysis. It produces a 5 Whys, a 4M1D and a fishbone analysis from the Kaizen's fields, linked records (Link Docs), uploaded files and Documents. You can then push the results to the Action Plan.
The root cause category you choose drives the root cause reporting and Pareto charts.