logging in or signing up Crash-course RCA Training rev 01 SidC Download Post to : URL : Related Presentations : Share Add to Flag Embed Email Send to Blogs and Networks Add to Channel Uploaded from authorPOINT lite Insert YouTube videos in PowerPont slides with aS Desktop Copy embed code: (To copy code, click on the text box) Embed: URL: Thumbnail: WordPress Embed Customize Embed The presentation is successfully added In Your Favorites. Views: 187 Category: Others/ Misc License: All Rights Reserved Like it (0) Dislike it (0) Added: January 14, 2011 This Presentation is Public Favorites: 1 Presentation Description No description available. Comments Posting comment... By: anitaabdhamid (11 month(s) ago) Dear Sir, Can I have a copy of this PPT. May e mail add is : anitaabdhamid@gmail.com Thank you. Saving..... Post Reply Close By: SidC (11 month(s) ago) Sure Saving..... Edit Comment Close By: Vinnie101 (13 month(s) ago) Please send me this presentation to vinniemb@gmail.com Saving..... Post Reply Close By: SidC (13 month(s) ago) Ok Saving..... Edit Comment Close Premium member Presentation Transcript QUALITY MANAGEMENT : QUALITY MANAGEMENT Date: Oct 09, 2009 CA / PA BASIC TOOLS CA/PA BASIC TOOLS Rev 01 10.08.09 ROOT CAUSE ANALYSIS A Crash-Course Slide 2: For most of us, it's a lot easier to jump to solutions, isn't it? Introduction Home Module 2 APPLICATION Objectives : Objectives Module 1: Participants will learn how to: Create and use Pareto chart in the analysis of a problem Implement steps for carrying out effective RCA Select and apply tools that support RCA Objectives : Objectives Module 2: Participants will be able to: Define and explain the 8 – D as a Problem Solving Method Apply the 8 Disciplines and Concepts Not included! HOME PAGE : HOME PAGE INTRODUCTION MODULE 1 MODULE 2 APPLICATION Slide 6: INTRODUCTION Module 1 Home Module 2 APPLICATION Introduction : Introduction Definition of Terms What it is Why use it RCA Process How to use it Introduction Home MODULE 2 MODULE 1 Terms and Definition : Terms and Definition Cause (causal factor) - a condition or event that results in an effect Direct Cause - cause that directly resulted in the occurrence Contributing Cause - a cause that contributed to the occurrence, but by itself would not have caused the occurrence Root Cause - cause that, if corrected, would prevent recurrence of a non-conformity and similar occurrences RCA Definition : RCA Definition Root Cause Analysis - a process designed for use in investigating and categorizing the root causes of events A process of tracing a Problem to its Origins Root Cause Analysis Process : Root Cause Analysis Process Step One: Define the Problem Step Two: Collect Data Step Three: Identify Possible Causal Factors Step Four: Identify the Root Cause(s) Step Five: Recommend and Implement Solutions Digging for the Root Causes : Module 1 Introduction Home Module 2 APPLICATION Digging for the Root Causes Module 1 Table of Contents : Module 1 Table of Contents Histograms and Pareto Chart Cause and Effect Diagram What it is How to use it Examples Summary MODULE 1 MODULE 2 APPLICATION Home Slide 13: Histograms- What it is A chart that graphically display the distribution of a set of data. Slide 14: Pareto Chart - What it is It reveals that a small number of NCNs are responsible for the bulk of quality issues, a phenomenon called the ‘Pareto Principle’. A Pareto chart allows data to be displayed as a bar chart and enables the main contributors to a problem to be highlighted. Slide 15: Pareto Chart – How to create it Gather facts about the problem Rank the contributions to the problem in order of frequency. Slide 16: Pareto Chart – How to create it (cont’n) Draw the value as a bar chart. Review the chart Redefine classifications if necessary. add a line showing the cumulative percentage of errors Slide 17: Chart 1 : The chart gives summary information and starts the cumulative % count at the top of the first bar: Pareto Analysis Example Slide 18: Example 2 : a series of Pareto charts drill down to more detail: 1st level Analysis gives “Design” as main cause of failure 2nd level Analysis gives breakdown of “Design” Pareto Analysis Example Slide 19: Example 3 : if the original Pareto is very flat, be prepared to cut the defects in a different way, here, it is 40:60 Pareto Analysis Example Slide 20: How it helps Pareto Analysis is a useful tool to: identify and prioritize major problem areas based on frequency of occurrence; separate the ‘vital few’ from the ‘useful many’ things to do; identify major causes and effects. The technique is often used in conjunction with Brainstorming and Cause and Effect Analysis. HINT ! The most frequent is not always the most important! Be aware of the impact of other causes on Customers or goals. Pareto Analysis Example Slide 21: Summary Pareto Charts provide a visual representation of the variables which contribute to problems or issues. Pareto Charts can be used as a prioritization tool to aid in focusing on the top issues which contribute to specific conditions. Pareto analysis is an approach which ranks the contributing factors and identifies which are the ones which have the most impact on a problem or issue. Often referred to as an approach for “separating the vital few from the trivial many”, sometimes referred to as the “80-20 rule” Process Steps A method for showing the distribution of quantitative data and identifying those with the greatest impact. Pareto Chart and Analysis Slide 22: CAUSE AND EFFECT Ishikawa/Fish Bone Diagram Cause and Effect : Cause and Effect Cause and Effect Analysis is a tool for identifying all the possible causes associated with a particular problem Valuable for: Focusing on causes not symptoms Providing a picture of why an effect is happening Establishing a sound basis for further data gathering and action Identifying all of the areas that need to be tackled to generate a positive effect Cause and Effect Sources of Variation : Cause and Effect Sources of Variation Sources of Variation is categorized as follows People Method Machine Material Environment Measuring System How to do it : How to do it 1. Identify the Problem/Issue 2. Brainstorm 3. Draw fishbone diagram Place the effect at the head of the “fish” Include the 6 recommended categories shown below How to do it (cont’n) : How to do it (cont’n) 4. Align Outputs with Cause Categories 5. Allocate Causes 6. Analyze for Root Causes 7. Test for Reality Tip ! The 6 categories recommended will address almost all scenarios. However, there is no one perfect set of categories. You may need to adapt to suit the issue being analyzed. Sources of Variation - People : Sources of Variation - People People The activities of the workers. Variations caused by skill, knowledge, competency and attitude Sources of Variation - Method : Sources of Variation - Method Method The methods used to produce the products. Variations caused by inappropriate methods or processes. Sources of Variation - Machine : Sources of Variation - Machine Machine The equipment used to produce the products. Variations caused by temperature, tool wear and vibration. Sources of Variation - Material : Sources of Variation - Material Material The "ingredients" of a process. Variations caused by materials that differ by industry, product and stage of production. Sources of Variation - Environment : Sources of Variation - Environment Environment The methods used to control the environment. Variations caused by temperature changes, humidity etc. Sources of Variation – Measurement System : Sources of Variation – Measurement System Measurement System The methods and instruments used to evaluate products. Variations caused by measuring techniques, or calibration and maintenance of the instruments. Cause and Effect Analysis Example : Cause and Effect Analysis Example Slide 34: Jumping to conclusion Failure to define problem Failure to find the root cause Weak problem solving No execution of corrective action PROBLEM SOLVING FAILURE Slide 35: Problem is clearly defined. Problem is accepted As an opportunity/challenge to improve True root cause is found Implemented an effective and irreversible corrective and preventive action Problem did not re-occur PROBLEM SOLVING SUCCESS Slide 36: Cause and Effect Diagram (Ishikawa) A visual brainstorming tool used to help identify and categorize potential root causes named for Kaoru Ishikawa. Action Reflection : $$$ Action Reflection Wait! I think I missed something It isn’t that they cannot see the solution, It’s that they can’t see the problem. Slide 38: Created by: Sid Calayag – Lead AuditorQuality Management System Presented by: Sid Calayag End of Presentation You do not have the permission to view this presentation. In order to view it, please contact the author of the presentation.
Crash-course RCA Training rev 01 SidC Download Post to : URL : Related Presentations : Share Add to Flag Embed Email Send to Blogs and Networks Add to Channel Uploaded from authorPOINT lite Insert YouTube videos in PowerPont slides with aS Desktop Copy embed code: (To copy code, click on the text box) Embed: URL: Thumbnail: WordPress Embed Customize Embed The presentation is successfully added In Your Favorites. Views: 187 Category: Others/ Misc License: All Rights Reserved Like it (0) Dislike it (0) Added: January 14, 2011 This Presentation is Public Favorites: 1 Presentation Description No description available. Comments Posting comment... By: anitaabdhamid (11 month(s) ago) Dear Sir, Can I have a copy of this PPT. May e mail add is : anitaabdhamid@gmail.com Thank you. Saving..... Post Reply Close By: SidC (11 month(s) ago) Sure Saving..... Edit Comment Close By: Vinnie101 (13 month(s) ago) Please send me this presentation to vinniemb@gmail.com Saving..... Post Reply Close By: SidC (13 month(s) ago) Ok Saving..... Edit Comment Close Premium member Presentation Transcript QUALITY MANAGEMENT : QUALITY MANAGEMENT Date: Oct 09, 2009 CA / PA BASIC TOOLS CA/PA BASIC TOOLS Rev 01 10.08.09 ROOT CAUSE ANALYSIS A Crash-Course Slide 2: For most of us, it's a lot easier to jump to solutions, isn't it? Introduction Home Module 2 APPLICATION Objectives : Objectives Module 1: Participants will learn how to: Create and use Pareto chart in the analysis of a problem Implement steps for carrying out effective RCA Select and apply tools that support RCA Objectives : Objectives Module 2: Participants will be able to: Define and explain the 8 – D as a Problem Solving Method Apply the 8 Disciplines and Concepts Not included! HOME PAGE : HOME PAGE INTRODUCTION MODULE 1 MODULE 2 APPLICATION Slide 6: INTRODUCTION Module 1 Home Module 2 APPLICATION Introduction : Introduction Definition of Terms What it is Why use it RCA Process How to use it Introduction Home MODULE 2 MODULE 1 Terms and Definition : Terms and Definition Cause (causal factor) - a condition or event that results in an effect Direct Cause - cause that directly resulted in the occurrence Contributing Cause - a cause that contributed to the occurrence, but by itself would not have caused the occurrence Root Cause - cause that, if corrected, would prevent recurrence of a non-conformity and similar occurrences RCA Definition : RCA Definition Root Cause Analysis - a process designed for use in investigating and categorizing the root causes of events A process of tracing a Problem to its Origins Root Cause Analysis Process : Root Cause Analysis Process Step One: Define the Problem Step Two: Collect Data Step Three: Identify Possible Causal Factors Step Four: Identify the Root Cause(s) Step Five: Recommend and Implement Solutions Digging for the Root Causes : Module 1 Introduction Home Module 2 APPLICATION Digging for the Root Causes Module 1 Table of Contents : Module 1 Table of Contents Histograms and Pareto Chart Cause and Effect Diagram What it is How to use it Examples Summary MODULE 1 MODULE 2 APPLICATION Home Slide 13: Histograms- What it is A chart that graphically display the distribution of a set of data. Slide 14: Pareto Chart - What it is It reveals that a small number of NCNs are responsible for the bulk of quality issues, a phenomenon called the ‘Pareto Principle’. A Pareto chart allows data to be displayed as a bar chart and enables the main contributors to a problem to be highlighted. Slide 15: Pareto Chart – How to create it Gather facts about the problem Rank the contributions to the problem in order of frequency. Slide 16: Pareto Chart – How to create it (cont’n) Draw the value as a bar chart. Review the chart Redefine classifications if necessary. add a line showing the cumulative percentage of errors Slide 17: Chart 1 : The chart gives summary information and starts the cumulative % count at the top of the first bar: Pareto Analysis Example Slide 18: Example 2 : a series of Pareto charts drill down to more detail: 1st level Analysis gives “Design” as main cause of failure 2nd level Analysis gives breakdown of “Design” Pareto Analysis Example Slide 19: Example 3 : if the original Pareto is very flat, be prepared to cut the defects in a different way, here, it is 40:60 Pareto Analysis Example Slide 20: How it helps Pareto Analysis is a useful tool to: identify and prioritize major problem areas based on frequency of occurrence; separate the ‘vital few’ from the ‘useful many’ things to do; identify major causes and effects. The technique is often used in conjunction with Brainstorming and Cause and Effect Analysis. HINT ! The most frequent is not always the most important! Be aware of the impact of other causes on Customers or goals. Pareto Analysis Example Slide 21: Summary Pareto Charts provide a visual representation of the variables which contribute to problems or issues. Pareto Charts can be used as a prioritization tool to aid in focusing on the top issues which contribute to specific conditions. Pareto analysis is an approach which ranks the contributing factors and identifies which are the ones which have the most impact on a problem or issue. Often referred to as an approach for “separating the vital few from the trivial many”, sometimes referred to as the “80-20 rule” Process Steps A method for showing the distribution of quantitative data and identifying those with the greatest impact. Pareto Chart and Analysis Slide 22: CAUSE AND EFFECT Ishikawa/Fish Bone Diagram Cause and Effect : Cause and Effect Cause and Effect Analysis is a tool for identifying all the possible causes associated with a particular problem Valuable for: Focusing on causes not symptoms Providing a picture of why an effect is happening Establishing a sound basis for further data gathering and action Identifying all of the areas that need to be tackled to generate a positive effect Cause and Effect Sources of Variation : Cause and Effect Sources of Variation Sources of Variation is categorized as follows People Method Machine Material Environment Measuring System How to do it : How to do it 1. Identify the Problem/Issue 2. Brainstorm 3. Draw fishbone diagram Place the effect at the head of the “fish” Include the 6 recommended categories shown below How to do it (cont’n) : How to do it (cont’n) 4. Align Outputs with Cause Categories 5. Allocate Causes 6. Analyze for Root Causes 7. Test for Reality Tip ! The 6 categories recommended will address almost all scenarios. However, there is no one perfect set of categories. You may need to adapt to suit the issue being analyzed. Sources of Variation - People : Sources of Variation - People People The activities of the workers. Variations caused by skill, knowledge, competency and attitude Sources of Variation - Method : Sources of Variation - Method Method The methods used to produce the products. Variations caused by inappropriate methods or processes. Sources of Variation - Machine : Sources of Variation - Machine Machine The equipment used to produce the products. Variations caused by temperature, tool wear and vibration. Sources of Variation - Material : Sources of Variation - Material Material The "ingredients" of a process. Variations caused by materials that differ by industry, product and stage of production. Sources of Variation - Environment : Sources of Variation - Environment Environment The methods used to control the environment. Variations caused by temperature changes, humidity etc. Sources of Variation – Measurement System : Sources of Variation – Measurement System Measurement System The methods and instruments used to evaluate products. Variations caused by measuring techniques, or calibration and maintenance of the instruments. Cause and Effect Analysis Example : Cause and Effect Analysis Example Slide 34: Jumping to conclusion Failure to define problem Failure to find the root cause Weak problem solving No execution of corrective action PROBLEM SOLVING FAILURE Slide 35: Problem is clearly defined. Problem is accepted As an opportunity/challenge to improve True root cause is found Implemented an effective and irreversible corrective and preventive action Problem did not re-occur PROBLEM SOLVING SUCCESS Slide 36: Cause and Effect Diagram (Ishikawa) A visual brainstorming tool used to help identify and categorize potential root causes named for Kaoru Ishikawa. Action Reflection : $$$ Action Reflection Wait! I think I missed something It isn’t that they cannot see the solution, It’s that they can’t see the problem. Slide 38: Created by: Sid Calayag – Lead AuditorQuality Management System Presented by: Sid Calayag End of Presentation