Root cause analysis in manufacturing is a systematic, scientific approach to determining the root cause of a problem encountered. By identifying the actual source of the problem, it is possible to find an effective solution for it – one that will stop the anomaly from recurring, rather than simply eliminating its current effects. Identifying the real cause of a problem is of extreme importance. Investing effort in eliminating causes of difficulties other than the original one, often leads to magnifying the number of starts. This, unfortunately, contradicts the principles of management according to the Lean methodology and goes against the economics of the company. Problem solving creates new business opportunities. It serves companies in improving themselves and increasing the value delivered to customers.
Why use root cause analysis in manufacturing?
Typical reasons for using root cause analysis in manufacturing include the inability to deliver a product, receiving negative comments from customers, a sudden drop in productivity, or unplanned production downtime. Conducting root cause analysis can take a considerable amount of time, unless specialized software is used. It is worthwhile for a company to take this type of action, because when the entire team is too hasty in finding a solution to a problem, without analyzing the source of the problem, a lot of waste can result. In addition, it can create further complications.
How to perform the analysis?
You can, of course, perform the analysis manually, unfortunately this is applicable to small companies. If you have a large production line, it is worth investing in specialized software for monitoring and root cause analysis in manufacturing. This will allow you to collect data directly from the machines and find the hidden factors affecting production efficiency.