Root Cause Analysis: A Step-By-Step Guide to Using the Right Tool at the Right Time, 1st Edition (Paperback) book cover

Root Cause Analysis

A Step-By-Step Guide to Using the Right Tool at the Right Time, 1st Edition

By Matthew A. Barsalou

Productivity Press

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pub: 2014-12-03
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Description

Although there are many books on root cause analysis (RCA), most concentrate on team actions such as brainstorming and using quality tools to discuss the failure under investigation. These may be necessary steps during RCA, but authors often fail to mention the most important member of an RCA team—the failed part.

Root Cause Analysis: A Step-By-Step Guide to Using the Right Tool at the Right Time provides authoritative guidance on how to empirically investigate quality failures using scientific method in the form of cycles of plan-do-check-act (PDCA), supported by the use of quality tools.

Focusing on the use of proven quality tools to empirically investigate issues, the book starts by describing the theoretical background behind using the scientific method and quality tools for RCA. Next, it supplies step-by-step instructions for performing RCA with the tools discussed in the first section. The book’s clear examples illustrate how to integrate PDCA with the scientific method and quality tools when investigating real-world quality failures.

This RCA guide provides root cause investigators with a tool kit for the quick and accurate selection of the appropriate tool during a root cause investigation. It includes an appendix with a guide to tool selection based on the intended use of the tool. There is also an appendix that defines the terminology used in the book.

After reading this book, you will understanding how to integrate the scientific method, quality tools, and statistics, in the form of exploratory data analysis, to build a picture of the actual situation under investigation that will lead you to the true root cause of an event.

The tools and concepts presented in the text are appropriate for professionals in both the manufacturing and service industries.

Table of Contents

INTRODUCTION TO ROOT CAUSE ANALYSIS

The Scientific Method and Root Cause Analysis

The Classic Seven Quality Tools for Root Cause Analysis

The Seven Management Tools

Other Tools for Root Cause Analysis

Exploratory Data Analysis and Root Cause Analysis

Customer Complaint-Related Root Cause Analysis

Example of a Root Cause Analysis

ROOT CAUSE ANALYSIS QUICK REFERENCE

Introduction to Root Cause Analysis

Introduction

Key Points

The Science of Root Cause Analysis

Hypothesis as a Basis for New Knowledge

Key Points

Scientific Method and Root Cause Analysis

Key Points

Experimentation for Root Cause Analysis

Key Points

The Classic Seven Quality Tools

Introduction

Ishikawa Diagram

Key Points

Check Sheet

Check Sheet with Tally Marks

Key Points

Check Sheet with Graphical Representations

Key Points

Run Charts

Key Points

Histogram

Key Points

Pareto Chart

Key Points

Scatter Plot

Key Points

Flowchart

Key Points

The Seven Management Tools

Introduction

Matrix Diagram

Key Points

Activity Network Diagram

Key Points

Prioritization Matrix

Key Points

Interrelationship Diagram

Key Points

Tree Diagram

Key Points

Process Decision Tree Chart

Key Points

Affinity Diagram

Key Points

Other Quality Tools for Root Cause Analysis

5 Why

Key Points

Cross Assembling

Key Points

Is-Is

Not Analysis

Key Points

Following Lines of Evidence

Key Points

Parameter Diagram

Key Points

Boundary Diagram

Key Points

Exploratory Data Analysis

Introduction

Key Points

Procedure

Stem-and-Leaf Plot

Key Points

Box-and-Whisker Plots

Key Points

Multi-Vari Chart

Key Points

Customer Quality Issues

Plan-Do-Check-Act for Immediate Actions

Key Points 8D Report

Key Points

Corrective Actions

Key Points

References

Appendix 1: Using the Tool Kit

Appendix 2: Terminology

Index

About the Author

Matthew Barsalou is employed by BorgWarner Turbo Systems Engineering GmbH, where he provides engineering teams with support and training in quality-related tools and methods, including root cause analysis. He has a master of liberal studies from Fort Hays State University and a master of science in business administration and engineering from Wilhelm Büchner Hochschule. His past positions include quality/laboratory technician, quality engineer, and quality manager.

Matthew Barsalou’s certifications include TÜV quality management representative, quality manager, quality auditor, and ISO/TS (International Organization for Standardization/Technical Specification) 16949 quality auditor as well as American Society for Quality certifications as quality technician, quality engineer, and Six Sigma Black Belt.

He is the American Society for Quality’s Statistics Division Newslettereditor and a frequent contributor to Quality Digest, the Minitab Blog, and has published in German, American, and British quality journals.

Subject Categories

BISAC Subject Codes/Headings:
BUS000000
BUSINESS & ECONOMICS / General
BUS019000
BUSINESS & ECONOMICS / Decision-Making & Problem Solving
TEC032000
TECHNOLOGY & ENGINEERING / Quality Control