Transcript Root Cause Corrective Action

Root Cause
Corrective Action
Workshop Objectives
1. Take a quick look at your experiences with RCCA
2. Quickly review Root Cause—Corrective Action
3. Discuss the problem of Holding the Gains
4. Approach to improve Corrective Action
Root Cause Corrective Action 2 .PPT
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Root Cause
Root
Eliminate Risk
Improved Quality
Costs Contained
Cause
Results Held
Found?
Root Cause Corrective Action 3 .PPT
Achieve Confidence
Does Not Return
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Were the Root Causes Found?
100% Problems Resolved?
Yes
100% Client Satisfaction?
Yes
Confident it Will Not Return?
Yes
Control in Place To Monitor?
Yes
Customer Satisfied?
Root Cause Corrective Action 4 .PPT
No
No
No
Improvement
No
No
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Corrective Action Key Issues
 A root cause of a process or product deficiency is one that is
understood and can be controlled.
 Once the root causes are found—the search to secure the
failure in all parts of your organization begins.
 When the search is complete you can then feel confident that
you will eliminate the cause and “hold the gains.”
Root Cause Corrective Action 5 .PPT
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What Are Root Causes?
Root Cause(s):
The variable(s) that can be proven and then controlled to
affect a change in a process or product that eliminates a
failure.
Root Cause Corrective Action 6 .PPT
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RCCA and the Juran Trilogy®
% of Costs Processes Deficient
The Juran Trilogy®
Design for
Root Cause -
Process
Quality
Corrective Action
Improvement
40
20
Breakthroughs
Chronic waste
COPQ
Root Cause Corrective Action 7 .PPT
Time
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How Does RCCA Fit In?
Scorecard and Data Management System
Identify
Strategic
Drivers
Assess
the
Current
State
Daily RCCA
Root Cause Corrective Action 8 .PPT
Deploy Policies and Standardize Work
Identify &
Establish
Projects
Design
and
Implement
Solutions
Achieve
and
Hold
Gains
Replicate
Spread,
Drive
Culture
Change
Projects:
 Lean VSM
 DMAIC
 DMADV
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Typical Control Process
Measure OK Compare to
actual
standards
performance
Established
control
standards
Not OK
Troubleshoot
Identify
problem
Root Cause Corrective Action 9 .PPT
Diagnose
cause
Remedy
cause
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Diagnosis
1. Move from a written description of the problem: a defective
part, an inaccurate drawing, a late delivery, a missed
target.
2. Measure the symptoms for the problem: part was
scratched, drawing was missing a spec, part was
delivered two days late, target was missed by$250,000.
3. Identify the potential causes (theories) of the symptoms: it
was scratched in shipping, it was scratched by the
inspector, it was scratched by the polishing machine, an
employee did not follow procedures…
4. “Get the facts to prove root cause”—collect the data,
conduct tests, monitor procedures…to prove the root
cause: the parts were scratched by the packing
materials in transit.
Root Cause Corrective Action 10 .PPT
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Follow the Defect Through the System
SUPPLIERS
Root Cause Corrective Action 11 .PPT
INPUT
YOUR
ORGANIZATION
OUTPUT
CUSTOMERS
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Do You Really Follow the Defect?
C
Multi-function
Team
Root Cause Corrective Action 12 .PPT
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A Control Plan
Root Cause Corrective Action 14 .PPT
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Next Steps
1. Follow your Control Plans
2. Follow the System
3. Think About Success Planning
Root Cause Corrective Action 15 .PPT
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