How to push teams beyond symptoms to uncover potential root causes

1. Cause & Effect How to p ush teams beyond symptoms to uncover potential root causes Anand Subramaniam

4. Definition Cause Any event or condition that anticipates or precipitates another event or condition Effect Any event or condition that is caused by another event or condition

5. Definition Event An occurrence or happening Condition A state of being, a set of characteristics or attributes

8. Cause & Effect - Roadmap Identify the Problem / Issue Brainstorm Draw fishbone diagram Align Outputs with Cause Categories Allocate Causes Analyse for Root Causes Test for Reality

9. C & E - Analysis Machine Method Manpower Materials Process knowledge Training / Competence Shift / Overtime Injuries Supervision / Communication Inadequate Space Damage / Misdirect Verification - Weight / Size Repeatability Positioning Accuracy Accuracy Mistake Proofing Feed Traffic Flow Speed Lost Time KPI Fork lift path Handling Incompats Type Weight Priority Setting 5S & 8W on Work Practices Repeatability Reproducibility Operating Procedures Missed Shipment Staff Shortage In & Out Bound Carry Over – AM / PM Missed Scans Roster Freight Types / Volumes Dangerous Goods

17. System & Process Causes System Causes Addresses how the management system allowed the process to become out of control Relates process factor causes to “weaknesses” in management systems policies / practices Process Causes Identifies factors and process that trigger the undesirable output Relates product output, (symptom), to process parameters, (causes)

18. Root Cause Analysis Level (Deep) Root Cause Consideration Tools Other (Wide) Product Defect/Detection cause Condition of controls to detect problem Control Barrier Analysis What other products have similar controls? Process Direct process cause, (trigger at process of origin Factors at process of origin triggering problem, (5Ms) Fishbone, (cause & effect) What processes have similar trigger cause? Plan Actual root cause, (led to trigger cause) Linkage to planning processes that trigger cause 5 Why with Hypothesis testing What other processes affected? System “ weakness” in mgt. policies or practices Linkage of mgt. system to actual cause System Cause Analysis Other affected mgt. policies