Root Cause Corrective Action
Workshop Objectives
1. Take a quick look at your experiences with RCCA
2. Quickly review Root CauseCorrective 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
Cause
Eliminate Risk
Improved Quality Costs Contained Results Held
Found?
Achieve Confidence
Does Not Return
Root Cause Corrective Action 3 .PPT
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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?
No
No
No Improvement
No
No
Root Cause Corrective Action 4 .PPT
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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 foundthe 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
Design for Quality
40
The Juran Trilogy
Process Improvement
Root Cause Corrective Action
20
Breakthroughs
Chronic waste COPQ
Time
Root Cause Corrective Action 7 .PPT
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How Does RCCA Fit In?
Scorecard and Data Management System
Assess the Current State Deploy Policies and Standardize Work Replicate Spread, Drive Culture Change
Identify Strategic Drivers
Identify & Establish Projects
Design and Implement Solutions
Achieve and Hold Gains
Daily RCCA
Projects: Lean VSM DMAIC DMADV
Root Cause Corrective Action 8 .PPT
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Typical Control Process
Measure OK Compare to actual standards performance Not OK Troubleshoot Identify problem Diagnose cause
Established control standards
Remedy cause
Root Cause Corrective Action 9 .PPT
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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 causecollect the data, conduct tests, monitor proceduresto prove the root cause: the parts were scratched by the packing materials in transit.
Root Cause Corrective Action 10 .PPT All Rights Reserved, Juran Institute, Inc.
Follow the Defect Through the System
SUPPLIERS
INPUT
YOUR ORGANIZATION
OUTPUT
CUSTOMERS
Root Cause Corrective Action 11 .PPT
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Do You Really Follow the Defect?
Multi-function
Team
Root Cause Corrective Action 12 .PPT All Rights Reserved, Juran Institute, Inc.
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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