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How do you conduct root cause analysis using tools such as fishbone diagrams, 5 whys, or fault tree analysis?

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Root cause analysis (RCA) is a method of identifying and solving the underlying causes of problems or failures in plant operations. It helps to prevent recurrence, reduce costs, improve quality, and enhance safety. There are various tools that can help you conduct RCA, such as fishbone diagrams, 5 whys, or fault tree analysis. In this article, you will learn how to use each of these tools and when to apply them.

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Jani Chetankumar

Co-Founder at Mechwat l Co-Founder at Commalinn
Gustavo Pino Avegno

Lidero la revolución verde en la gestión de residuos, agua y energía ‖ Impulso plantas industriales a un modelo de…

1 Fishbone Diagrams

A fishbone diagram, also known as an Ishikawa diagram or a cause-and-effect diagram, is a graphical tool that helps you organize and display the possible causes of a problem or effect. It resembles a fish skeleton with the head representing the problem or effect and the bones representing the categories and subcategories of causes. To create a fishbone diagram, you need to define the problem or effect clearly and write it in a box at the right end of the diagram. Then draw a horizontal line from the box to the left end of the diagram, which is the spine of the fish. Identify major categories of causes that contribute to the problem or effect, such as people, equipment, materials, methods, environment, and measurement. Write these categories along the spine and draw diagonal lines from them. For each category, brainstorm possible subcategories and specific causes that relate to the problem or effect. Write these subcategories and causes along the diagonal lines and draw smaller lines from them. After analyzing the diagram, identify which causes need further investigation or action.

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Jani Chetankumar

Co-Founder at Mechwat l Co-Founder at Commalinn
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After a decade immersed in using fishbone diagrams for root cause analysis, I can vouch for their vital role in dissecting complex issues. These diagrams aren't just tools; they're structured pathways to uncover the heart of a problem. Challenges do exist, like oversimplifying intricate issues or missing interconnected causes. Yet, the benefits are profound. They foster collaborative problem-solving, unveil hidden triggers, prioritize actionable steps, and drive efficient resolutions by addressing core issues, not just surface symptoms.

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2 5 Whys

The 5 whys technique is an effective tool for discovering the root cause of a problem or effect. To use this technique, you must define the problem or effect clearly and write it down. Then, ask “why” and record the answer. If this answer is not the root cause, ask “why” again until you reach the underlying cause or until asking “why” no longer yields a useful answer; usually, this takes five or fewer whys. Lastly, verify that the root cause is valid by testing it with a counterfactual question. For example, if the root cause is “the valve was not closed properly”, ask “if the valve was closed properly, would the problem or effect have occurred?” If the answer is “no”, then you have found a valid root cause.

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Gustavo Pino Avegno

Lidero la revolución verde en la gestión de residuos, agua y energía ‖ Impulso plantas industriales a un modelo de excelencia operativa ‖ Docente ‖ Mentoría green skills ‖ Experiencia internacional +9 LATAM, EE.UU. y UE.
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El método de los 5 porqués es una herramienta potente que se puede utilizar para realizar un análisis de causa raíz. Es una forma de preguntar "?por qué?" cinco veces seguidas. Cada vez que obtienes una respuesta, la utilizas como la base para tu siguiente pregunta. No siempre es fácil identificar la causa raíz de un problema, pero es importante hacerlo para poder resolverlo de manera efectiva. Algunos detalles a considerar de la metodología de los 5 porqués: 1. Involucrar a las personas que están directamente involucradas en el problema. 2. Reunir datos y evidencia para respaldar tus conclusiones. 3. Ser objetivo y no asumir que ya sabes la causa raíz del problema.

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Jani Chetankumar

Co-Founder at Mechwat l Co-Founder at Commalinn
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The 5 Whys technique? Absolutely crucial. It's like peeling an onion, going layer by layer to get to the core of a problem. Challenges? Sometimes it's too easy to stop early or miss the bigger picture. But the benefits? Oh, they're game-changers. It helps us really grasp what's causing issues, uncover hidden connections, and zero in on effective fixes. It's a simple yet adaptable method that's key for problem-solving and making things better.

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3 Fault Tree Analysis

A fault tree analysis (FTA) is a logical tool that helps you analyze the probability and consequences of a failure or an undesirable event. It uses a tree-like structure, with the failure or event at the top and possible causes at the lower levels, as well as symbols to represent the logical relationships between the causes. To create a fault tree analysis, you should begin by defining the failure or event clearly and writing it in a box at the top of the diagram. Then, identify the immediate causes that can lead to it, based on your knowledge, experience, or data. For each immediate cause, identify the sub-causes that can lead to it and repeat this process until you reach the basic causes that are not further decomposable or controllable. Assign probabilities or frequencies to each cause based on your data or assumptions and calculate the probability or frequency of the failure or event. Finally, evaluate the results and identify which causes need further investigation or action.

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Jani Chetankumar

Co-Founder at Mechwat l Co-Founder at Commalinn
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You know, in plant operations, Fault Tree Analysis (FTA) is a lifesaver. It's like diving into a maze of potential failures to keep things ticking. But, gotta admit, it's not all smooth sailing. Tracing those connections in complex systems and nailing down accurate data can be a real challenge. Yet, the payoff? Huge. It helps us see risks coming, take spot-on action, and keep everything humming. And hey, the future's looking bright—integrating AI into FTA? That's promising smarter ways to predict and safeguard plant operations.

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4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Akshaykumar Pandhare

Dy. Operations manager @ Dmart| India's most profitable retail chain| EX- TPM World class manufacturing factory Coordinator| Lean Six Sigma Green Belt| +91 7841855788
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Root causes analysis by '5w1h, 4m and 5 why' method is the very common and effective way to find the root cause of the problem. 1. In 5W1H we come to know the problem statement by asking questions What , when , where, who, whom and How and in some cases how many. 2. Also consider involved persons observations during problems happening and if possible sketch the drawing. 3. Then take that problem statement to the fishbone diagram and do brainstorming and gemba. 4. Find out all possible causes for problem statements and mark them as high, low and medium probability. 5. Then all that sort out into the 4M/6M. 6. Then most possible causes take for 5why analysis and ask why until you get root cause and give a countermeasure solution above CML 3.

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How do you conduct root cause analysis using tools such as fishbone diagrams, 5 whys, or fault tree analysis?

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4 Here’s what else to consider

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How do you conduct root cause analysis using tools such as fishbone diagrams, 5 whys, or fault tree analysis?

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4 Here’s what else to consider

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