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Root Cause
Analysis
Many
manufacturing organizations experience high costs due to poor process yields and
ineffective corrective action systems. The manifestations of this problem
include repetitive nonconformances, overflowing MRB cribs, long stays in MRB,
delinquent deliveries, and high warranty costs.
Root
Cause Analysis
is
a one-day program focused on solving product and process problems in
engineering development and manufacturing organizations.
The program integrates the activities of engineers, quality
engineers, manufacturing engineers, production supervisors, production
lead personnel, buyers, contract administrators, and others to identify
and eliminate failure root causes in products, manufacturing processes,
and administrative processes. This program meets ISO and Boeing
D1-9000 (Revision A) requirements.
Materials
Who
Should Attend
Production
supervisors, production lead personnel, quality engineers, MRB coordinators,
manufacturing engineers, contract administrators, and procurement personnel
should attend this training.
Root
Cause
Analysis Syllabus
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Module
1: What is the Problem?
The nature of a problem. Problems
versus symptoms. Product and
process nonconformances. The
Four-Step Problem-Solving Process.
Defining the problem. Corrective
action versus Band-Aid fixes. Problem-solving
approaches and common shortfalls. The
high cost of the hidden factory. Problem
definition. Class exercise.
-
Module
2: Finding Root Causes.
Brainstorming. Mind
mapping. Force-field analysis.
Flow charting. Ishikawa
diagrams. Fault tree analysis.
Finding and using available data.
Soliciting and listening to shop floor input.
Team concepts. Developing
synergy. Meetings and action
plans. The Root Cause
Assessment and Assignment matrix. Tapping
internal and external resources. Knowing
when to ask for help. The
nature of variability. In-house
root cause identification class exercise.
-
Module
3: Corrective Action.
Corrective action definitions. Corrective
action order of precedence. Advantages and disadvantages of design
modifications, process modifications, procedural modifications, requirements
relaxation, screening, and other potential corrective actions.
Evaluating corrective action effectiveness.
Inspection caveats. Corrective
action class exercise.
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Module
4: Corrective Action
Requirements.
ISO 9001 root cause identification and corrective action
requirements. The ISO 9001
Management Review. Pareto
analysis. Material review,
disposition, and corrective action. Material
review, disposition, and corrective action class exercise.
Course overview and summary. Course
critique.
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