How to Conduct a Root Cause Analysis

A step-by-step guide (with examples)

When an issue arises, it’s important to take quick action. Whether that means launching a software patch, pulling a batch, or halting the use of a reagent, it’s critical to tackle the immediate problem.

But just as critical as “How do we fix this?” is “How do we make sure this doesn’t happen again?”

That’s where the root cause analysis (RCA) comes in. This guide walks you through conducting an effective root cause analysis that takes you from “problem fixed” to “process improved.”

What is a root cause analysis?

“Root cause analysis” is just a fancier way to say, “Find out why this issue really happened.”

Instead of just treating the symptoms, a root cause analysis aims to identify the ultimate reason a problem occurred so you can take steps to prevent the issue from arising again.

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Root Cause Analysis

This is a good article. I have three tongue-in-cheek additions:

1. For chemical process analysis, question the instrument, then the instrument operator, then the process equipment, then the process operator, then the area manager, then the plant manager. Always equipment before people. In the end, if the problem doesn't go away, fire the plant manager.

2. Another approach I call the Magnusson method. Call the team together and solicit solutions. Act on every good idea. If the problem goes away, retire to the bar to reach a consensus regarding which action solved the problem. If the solution merely hides the problem, guess how long it will take for the product/service customer to discover what happened and find a new supplier.

3. You haven't said anything about really large political problems, illegal immigration for example. Now suppose you were assigned to determine the root cause of this issue in the US. And suppose you are a lifelong politician having no subject matter expertise. And suppose further the assignment came with a wink and a nod. What would you do? Would eQMS help? Should you just ignore the assignment other than doing a border flyover? Perhaps issue several "word salads"? Perhaps run for higher office which would allow you to assign someone else to the problem? Or go back to process 1, fire the manager, hire a new one, discover the scrap pile of uninstalled steel wall plates is still in place, install it, and ask the operators to do their job.