Root Cause Analysis

Manufacturing Training Seminars

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J.H. Berk and Associates

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

Root Cause Analysis (presentation charts and related class materials), ManufacturingTraining Seminars, 2007.

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

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.
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.

*The above training can be customized to meet your requirements.* *Need a guest speaker for an important luncheon or dinner meeting? Please contact us.* *Any questions? Please call us at 909 204 9984 or contact us via e-mail.*
	An unending focus on cost reduction is what makes businesses survive and thrive in good times and bad. Our newest book, Cost Reduction and Optimization for Manufacturing and Industrial Companies, was published in January 2009 by Scrivener Publishing and Wiley. This is a hands-on, no baloney, rapid road map approach for any organization interested in identifying and acting on cost reduction opportunities. The book focuses on design, process, supplier, and overhead areas. In addition to providing roadmaps in each area, this book identifies the risks (and actions to control risk) for each recommendation. As an added feature, Excel templates for the quantitative assessment techniques included with this book can be downloaded here. (If you need help with this template, just give us a call at 909 204 9984.)
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	Quality Management for the Technology Sector focuses on implementing quality management techniques with proven track records. This 1-day seminar focuses on quality measurement, root cause corrective action techniques (including FMEA, FTA, and SFA), defining customer expectations (including QFD), using statistical techniques (including SPC and DOE), supplier teaming, and the latest quality standards (including ISO 9001:2000). The program is based on Quality Management for the Technology Sector (Butterworth-Heinemann, 2002), our hands-on, practical guide to implementing effective quality management tools. I would highly recommend this book not just to quality assurance professionals, but to professionals in all disciplines. - John W. Gozza, Quality Assurance Manager, Composite Structures LLC
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