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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