(Mfg.) Root Cause Failure Analysis Training


In our RCFA class you can learn a methodical, proven, effective method to isolating root cause to your failures and implementing new standard work to prevent reoccurring failures.

“Let me get this straight … our team just spent $ 50,000 on tooling to correct quality defects and this RCFA team discovered that tooling isn’t the problem?

This is a story from one of our clients and their team proceeded to document (28) different machine adjustments that allowed their Y = f(x) RCFA project to be successful.  It’s also a great example of separating the ‘trivial many’ down to the ‘vital few.’

RCFA is Built on the Scientific Method

Plan – Think Hypothesis
Do – Think Experiment, Trial
Check – Think Study and Reflect
Adjust – Think Standardize

In RCFA we ask some basic questions:

  • Where is the problem located?
  • How big is the problem;
  • What data is available?
  • Where new data is needed, how will we collect it?
  • What tools and approach do we need to fix the problem?
  • How do we test our solution to ensure the problem has been addressed?

From there, we move into a formal problem statement.  Problem statements need the following:

  • Relate to the performance of the organization
  • Not prescribe a solution
  • Be of a size that is small and manageable

Here is an example:

Inserter X fails to install foil correctly in the product. Potential causes are products not feeding correctly, improper storage of foils, half moon errors, and others the team will investigate. Failures have caused 28.1% unscheduled downtime to a standard on 10% for the inline product machines 1 & 2. These failures resulted in (15) late deliveries and (3) customer complaints. Total impact is expedited freight and credits totaling $11,102; Maintenance spending has exceeding $50,000 to repair/fix the die tooling **without** improved daily finished output.


5 Days

Related TGG Services:


Define your Problem Statement.

The first step towards breaking your organizational log jams is identifying and verbalizing the challenge you're facing. What are you trying to solve? This simple Problem Statement exercise can have profound implications for your team. It helps you define the issue and gives TGG some sense of where the soft spots could be in your Order to Cash process. We invite you to take a few moments to fill out this form. A TGG consultant will contact you shortly to discuss your Problem Statement and provide some insight on how we may be able to help.

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