Objectives of the session

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Presentation transcript:

KAIZEN Step 3: “Root Cause Analysis” KAIZEN Training of Trainers 2015 KAIZEN Facilitators’ Guide Page __ to __ .

Objectives of the session At the end of the session, trainees are able to: Describe importance of identifying root causes of the contributing factor(s) Describe how to practice root cause analysis by developing and utilizing Fishbone diagram Demonstrate the process of root cause analysis at their working place

KAIZEN Process 7 6 5 4 3 Root Cause Analysis 2 1 Standardization STEP 7 Standardization STEP 6 Check effectiveness of countermeasure STEP 5 Implementation of countermeasure STEP 4 Identification of countermeasure STEP 3 Root Cause Analysis STEP 2 Situation Analysis STEP 1 Selection of KAIZEN theme

KAIZEN Step 2 and Step 3 1 1 KAIZEN Step 2 KAIZEN Step 3 2 3 2 4 5 Find root causes of the contributing factor(s) Identify the contributing factors Prioritize the contributing factor(s) to be solved KAIZEN Step 2 KAIZEN Step 3

Cause-Effect diagram (Fish bone diagram) It is developed by Prof. Kaoru Ishikawa It connects “effect” and “cause(s)” systematically with line Clarification of relations between effect and cause(s)

Two types of Fishbone diagram Fishbone diagram for Management It is aimed for prevention of possible problem not yet occurred. It is also aimed to identify factor to be control. It does not need to ask why-because question Fishbone diagram for Problem Solving It is aimed to find root causes of problem already occurred It is developed based on data and information obtained from Step 2 Find root causes that are affecting the major contributing factor(s)

Steps of root cause analysis (1) Put effect (= the major contributing factor) in the step 2 as ”head of fish”; “Why (the contributing factor) happened?” Draw heavy line from left to the effect on the center; ”Backbone of fish” Why (the contributing factor) happened?

Steps of root cause analysis (2) Determine large category of cause according to your working environment MSHEL group; Management, Software, Hardware, Environment 4M group; Man, Machine, Material, Method Environment Human Why (the contributing factor) happened? Hard (machine/equipment) Soft (System and methodology)

Example of grouping of causes Human: knowledge, skills health conditions, physical conditions etc. Soft: system, methodologies, mechanism etc. Hard: material, equipment, furniture, tools etc. Environment: facility environment (water supply, electricity, smell, humidity etc.), working environment (work space, accessibility of materials, arrangement etc.)

Steps of root cause analysis (3) Seek possible causes for the effect (the primary cause) Categorize the primary cause into category Avoid to mention to things in terms of “recourse shortage” Environment Human Why (the contributing factor) happened? Hard (machine/equipment) Soft (System and methodology)

Steps of root cause analysis (4) Narrow down cause(s) of each primary cause (the secondary cause) Avoid to mention to things in terms of “resource shortage” Environment Human Why (the contributing factor) happened? Hard (machine/equipment) Soft (System and methodology)

Steps of root cause analysis (5) Find out “root causes” by asking “Why it is happening?” in enough time (recommended 5 times) for each possible causes listed on primary branch, and branch them into secondary, tertiary. One Human Two Three Make circle on it! Why (the contributing factor) happened? This is Root cause Four Five times!!

Example of Fishbone diagram Environment Human Why (the contributing factor) happened? Hard (machine/equipment) Soft (System and methodology)

Continue asking “Why-Because” in 5 times One cause might have more than 2 causes The most major contributing factor on the right side “Why (_____) happens?” The categories can be determined according to your situation

Remarks on development of Fishbone diagram Effect = Major Contributing factor, which was identified in Step 2, and Effect is not equals to “KAIZEN Theme”, identified in Step 1 If two contributing factors account for 80% (Pareto rule) in the step 2, it is necessary to develop two fishbone diagrams

Cont. When repeat “Why~? – Because~” in 5 times, situation of own workplace need to be thought before searching a cause of others While analyzing root causes, it is necessary to avoid blaming other sections; KAIZEN is for own

Cont. Avoiding mentioning “shortage of resources”; “No money”, “No human resource”, “No material” etc. Finding root causes should not be done with your instincts and senses. Your experiences, knowledge, and information should be used

The problem will never be solved!! If root cause(s) are not identified properly, any countermeasures could not be come up with… The problem will never be solved!!

Let us try to develop Fishbone diagram