Written By: Jon Wellik, EMBA, LSSBB, UW–Madison InterPro
Do you and your company encounter the same problems over and over again? Does your organization tend to limit its use of root cause analysis (RCA) to only specific aspects of the operation? If so, you are not alone. Many companies overlook utilizing this valuable tool across the organization, leaving pervasive and systemic issues unresolved.
The good news is there are many examples from various industries that show positive work culture can be greatly influenced by incorporating RCA into daily work and across the entire business. World-class companies tend to be world-class problem solvers. Some examples include:
- Toyota, renowned for its “Toyota Production System” which heavily incorporates RCA to identify manufacturing defects and optimize production processes.
- The Mayo Clinic, which utilizes RCA to analyze medical errors and patient incidents, leading to improved protocols and patient care.
- JP Morgan Chase, which uses RCA to analyze operational risks and compliance issues to mitigate financial losses.
- GE, which uses RCA across its diverse manufacturing operations to identify and address quality issues, optimizing production efficiency.
RCA is the process of identifying the source(s) of a problem to provide corresponding solutions at the root level, with a goal of preventing recurrence. The most frequently used RCA tools are 5 Why, Pareto Analysis, Cause Mapping, A3, Fishbone, and Fault Tree Analysis. All are based on the RCA Process as shown:
Step 3 is at the heart of RCA, and how effectively it is carried out often determines the strength of the outcome. Adding an event timeline of the factors that led to the problem can be helpful in identifying direct and indirect causes.
Below are three recommendations to sustain a problem-solving culture within RCA:
Ensure RCA and the problem-solving process are included in your company strategy.
Having a strategic point of reference is critically important to guide, align, and motivate activity throughout any organization. Consider including the below RCA types which are most often overlooked:
- Production-based RCA: Root cause investigations as to why abnormalities or defects are present either within the manufacturing process or finished product.
- Process RCA: Analysis is utilized to improve business processes such as improved work schedule flexibility solutions, or improved communication.
Implement the right performance tracking systems.
Within the strategic frameworks mentioned above, it is no coincidence that what you track is what you improve. Establish the right key performance indicators to provide direction and motivation; if you combine this with a continuous improvement culture, you will be unstoppable, particularly in the face of your competition.
Invest in training and development.
Training dollars can – and should – be justified with a bit of diligence, through a Return on Investment (ROI) approach. Facilitate team involvement to develop realistic improvement plans, including RCA training.
If you’d like to continue your work with RCA, including hands-on experience and discussions with industry professionals, consider joining UW–Madison’s Interdisciplinary Professional Programs for the Root Cause Analysis Tools for Technical Applications course. This 2-day offering is part of the Technical Leadership Certificate and the Maintenance and Reliability Management Certificate programs.
Root Cause Analysis Tools for Technical Applications
Reach out to Jon Wellik, Program Director for the Maintenance and Reliability Management and Technical Leadership Professional Development Programs, for questions about specific offerings and certificates.