Q: I am looking for samples of a RCA. I will be doing training on that topic and I would like to have some samples to use with the participants.
A: Thank you for contacting ASQ and the Quality Information Center. I received your request for samples of root cause analysis. Root cause analysis is defined as a “quality tool used to distinguish the source of defects or problems. It is a structured approach that focuses on the decisive or original cause of a problem or condition” (from The Quality Improvement Glossary by Donald L. Siebels).
I found over 100 resources on RCA in the ASQ Knowledge Center (if you would like to browse through them all, here is the link to my original search results). I thought you might be most interested in case studies which provide examples of how root cause analysis has been used. I found almost 40 case studies which focus on root cause analyais and I’ve listed some case studies below which I thought would be helpful:
- “Eastman Chemical’s Success Story“, Quality Progress, June 2003 (open access)
Abstract: Customer Complain investigations weren’t getting to root causes. Logic trees proved more effective than fault trees in determining what actually went wrong. After root cause analysis, complaint numbers dropped by half. That and indirect benefits led to bottom-line results.
- “Molding a Solution“, Six Sigma Forum Magazine, August 2012 (open access)
Abstract: The authors used Six Sigma to improve the process of manufacturing gear boxes for mechanical power transmission at a foundry in India. The goal was to improve product performance by reducing variation in the casting of components, thereby reducing defects. The analyze phase used root cause analysis and failure mode and effect analysis to identify several process variables, including pattern design and maintenance, worker training, and the proportions of scrap and coal inputted into the molds, that were increasing the frequency of the major defects.
- “Wind Power Company Gets to the Root of an Icy Issue” ASQ Case Study, April 2010 (open access)
Abstract: A root cause analysis project saved Clipper Windpower $1 million in lost revenue. By identifying the root causes of turbine failure during inclement weather, Clipper increased customer satisfaction through improved turbine availability. This project also supported a key supplier’s quality process, as Clipper’s team helped redesign and test an improved anemometer. Team members mastered quality tools and strategies, preparing them for future improvement projects.
- “Regional Team Approach Helps Energy Company Enhance Safety, Avoid Costs“, ASQ Case Study, August 2006 (open access)
Abstract: Cross-functional teams identified root causes of injuries and reduced accidents by 48 percent in one year while saving an estimated $714,000 in cost avoidance over a 24-month period. To compile data and identify root causes, team members used trend graphs, Pareto diagrams, bar charts, and fishbone diagrams. A key tool used in developing an action plan was the solution selection matrix, a systematic approach that allows for the best possible solutions to surface.
- “Column: One Good Idea: Use Run Charts to Confirm Root Causes“, Quality Progress, February 2001 (open access)
The following webcasts may also be helpful for those who are new to root cause analysis:
I hope that this information is helpful. Please feel free to contact me with any questions or if you need additional assistance.
ASQ Research Librarian