Root Cause Analysis Sample

CHAPTER – 1
INTRODUCTION
Root Cause Analysis (RCA) is the process of identifying causal factors using a structured approach with techniques designed to provide a focus for identifying and resolving problems. Every process or equipment failure happens due to a number of reasons. This failure is preceded by a series of actions and consequences. Hence, root cause analysis is nothing but a step-by-step method or process that leads to the discovery of faults or root cause. Using the analogy of a detective investigating and solving a murder, an RCA investigation traces the cause and effect path from the failure back to the root cause. Tools, techniques and methods that help organisations, groups or individuals in identifying the root causes of problems

If these issues go unattended, it leads to a lot of abnormality and inefficiencies which ultimately leads to rejection.
Multistage manufacturing process is one in which the products are produced under multiple setups. Hence the flow of information related to quality of the product and process faults is very complicated. Therefore the identification of root causes in multistage manufacturing is very hard but on the other hand implementation of Root Cause Analysis on single stage manufacturing is easy and effective.
To understand and apply my knowledge of Root Cause Analysis, I have undertaken a case study of an industry which was in a very bad condition. The industry faced frequent breakdowns which affected their annual sales by 5.19%, the no of customer complaints reached 367pa, line balancing delay contributed 27%, rejection rose to 3.03% of sales and various other factors which led to the downfall of the industry. Therefore, the Root Cause Analysis was undertaken to improve the plant situation and the same was applied to the cell of CNC Oxy Flame Cutting machine

If it is repeated, has it reoccurred at the certain intervals or not. If the causes have re-occurred have they occurred at a particular position. To put it in a nut shell, this tools tries to analysis as to why was there a variation from the specified specifications in th first place. The main objective of a Multi Vari Analysis is to reduce a large number of unknowns and unmanageable causes of variation to a much smaller family of related variables containing the controlling