Root Cause Analysis
2 Days

Course Description and Audience:
This course is designed for all employees at all levels who are involved in systematic
process improvement and DMAIC problem solving. Topics include guidelines for
systematic problem solving, root cause analysis and basic quality tools. Course is
also an excellent introduction to six sigma basics and lean methodologies. This
course is appropriate for both business process and manufacturing process
excellence activities.

 

Course Objectives:
Upon completion of the course the participants will be able to:

  1. Identify a problem that requires improvement.
  2. Define a problem in measurable terms.
  3. Contain the problem while developing a long-term solution.
  4. Collect and analyze data relevant to the problem of interest.                    
  5. Analyze the system of causes and determine root cause.
  6. Plan and implement solutions relevant to the root cause of the problem.
  7. Evaluate the effectiveness of the improvement and the elimination of waste.
  8. Determine opportunities for standardization.
  9. Discuss how to realize the benefits of process improvements.
  10. Examine the improvement process for lessons learned and new problems to solve.

Software: JMP, Microsoft Excel
Prerequisites:  None

Detailed Course Outline:
  
Define and Contain the Problem                                                    
Introduction to Root Cause Analysis and Six Sigma
Define the Problem
Contain the Problem
State the Problem, Objective, Goal, and Benefits
Perform Resource Analysis
Develop a High-Level Process Map
                                                
Measure the Problem
Define Data Collection Requirements
Process Reviews and Mapping
Develop a Data Collection Plan
Define the Process Baseline 
                         
Analyze the Data and Determine Root Cause
Analyze All Relevant Data
Explore All Probable Root Causes
Determine and Summarize the Root Cause  
                                                     
Improve Performance
Identify Owner and Opportunities for Standardization
Determine the Controls Needed to Sustain the Gains
Realize the Benefits of Improvement
Reflect on the Improvement Process      
                                                           
Control and Standardize Improvements
Identify Owner and Opportunities for Standardization
Determine the Controls Needed to Sustain the Gains
Realize the Benefits of Improvement
Reflect on the Improvement Process                 
                                              
Lean Basics
Identification of Waste
Value Stream Mapping
Lean Performance Measures
Lean Solutions