George Kakar

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In industrial manufacturing, Root Cause Analysis (RCA) tools are misunderstood by many.

In my experience, the RCA process on the production floor will dictate how the information is gathered from the first line of defence (operators), what the resolution steps look like (technical teams) and how the problem is resolved in the future (documentation).

What are the most utilized RCA methodologies?

🙋 𝟓 𝐖𝐡𝐲𝐬

The premise of the “5 Whys” is simple | Start with “Why has the problem occurred?” and proceed to ask “why” five times as you dig deeper into the root cause and document the answers along the way.

🐟 𝐅𝐢𝐬𝐡𝐛𝐨𝐧𝐞 𝐃𝐢𝐚𝐠𝐫𝐚𝐦

Outline the core and sub-factors that contribute to the main problem. The fishbone template is often adapted to the team. In other cases, it's just a set of lines resembling a fish's skeleton.

𝗪𝗵𝘆 𝗱𝗼 𝘁𝗵𝗲𝘀𝗲 𝘁𝗼𝗼𝗹𝘀 𝗳𝗮𝗶𝗹?

- RCA is a methodology rather than a rigid protocol to be followed. It must be adapted to the team and problem at hand.

- The concept of RCA is straightforward. We’re looking to uncover, resolve, and document the issue. Mastering the process takes time. Spending the effort in training, evaluating, and supporting the team looking to implement these tools is essential. Many groups will abandon these tools before they realize the benefit.

- I’ve seen many poor incentive implementations - Ex: the team member that conducts the most RCAs over a period (ex: 1 week) will receive a gift card. This leads to a focus on quantity over quality. Without proper guardrails, teams waste their time and fail to learn from the RCA initiatives they conduct.

𝑾𝒉𝒂𝒕’𝒔 𝒕𝒉𝒆 𝒔𝒐𝒍𝒖𝒕𝒊𝒐𝒏?

Ironically... “𝘴𝘵𝘢𝘳𝘵𝘪𝘯𝘨 𝘸𝘪𝘵𝘩 𝘸𝘩𝘺” 𝘪𝘴 𝘵𝘩𝘦 𝘧𝘪𝘳𝘴𝘵 𝘴𝘵𝘦𝘱. In other words, communicating why we’re looking to implement these methodologies is critical. The goal isn’t to fill out a five-step document outlining the issue. The goal is to clearly understand each component of the problem and build a skillset of troubleshooting & communication.

Explain the "why" > Train > Implement > Assign Owners > Evaluate > Adjust

𝗝𝗼𝘂𝗿𝗻𝗲𝘆 > 𝗗𝗲𝘀𝘁𝗶𝗻𝗮𝘁𝗶𝗼𝗻

Ownership & Mentorship are critical. Having the responsibility placed on the individual and supporting him to understand what can be improved is critical in establishing these tools. Without both, plants fail to accomplish the cultural shift required to improve.

What have you seen when it comes to RCA tools in production environments? Any lessons when it comes to success or failure? What has worked for your teams?

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AS WE ALL WELCOME THE NEW YEAR 2023
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Akaekpuchionwa on TikTok Akaekpuchionwa's short video with ♬ original sound

Dear friends,
Don't underestimate the value of having a good team!
You don't become successful on your own.
You have to rely on really good people.

Dear friends,
'The problem with the world is that the intelligent people are full of doubts, while the stupid ones are full of confidence.

This is an awesome In my opinion,! The truth needs to be told!. Fixed the country and fix your attitude and mind goes together, one doesn't go alone. Don’t wake up and recognize that it was the only politicians who created our problems. If the law is not caught you might think to say there’s no law in Ghana.
Progress is impossible without change and those who cannot change their minds cannot change anything. Change isn't the same as progress, but progress is impossible without change. In other words, you can't make progress or move forward if you don't keep moving.
If you're not changing, you're regressing. If you're not doing something new, then you'll end up doing the same thing over and over again until it stops working. That's when you look around and realize that everything has changed except for you!
The only way to make progress is by letting go of what doesn't work and adopting new habits that do work. The only way to let go of what doesn't work is by making a conscious decision to let it go and then sticking with it until it becomes second nature. The only way to stick with something until it becomes second nature is by showing up every day and doing the work until it no longer feels like work.
You can disagree. Much progress has been achieved through stubborn people hell-bent on something. Whether or not change is considered good or bad is up to interpretation.

'STOP BEING AFRAID OF WHAT COULD GO WRONG, AND START BEING EXCITED OF WHAT COULD GO RIGHT.