{"id":3937,"date":"2025-03-21T03:37:17","date_gmt":"2025-03-21T09:37:17","guid":{"rendered":"https:\/\/limblecmms.com\/?p=3937"},"modified":"2025-05-30T12:59:01","modified_gmt":"2025-05-30T18:59:01","slug":"root-cause-analysis","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/root-cause-analysis\/","title":{"rendered":"How to Do Root Cause Analysis"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<span style=\"font-weight: 400;\">Conducting a <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> (<\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\">) helps trace recurring problems to their source. It begins with identifying a problem. Next, data collection helps you to pinpoint the root cause and take <\/span><span style=\"font-weight: 400;\">corrective action<\/span><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In <\/span><span style=\"font-weight: 400;\">healthcare<\/span><span style=\"font-weight: 400;\">, <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\"> ensures that doctors address the <\/span><span style=\"font-weight: 400;\">underlying causes<\/span><span style=\"font-weight: 400;\"> of conditions instead of wasting their time on symptoms alone. The same principle applies in manufacturing, facilities maintenance, and any other industry.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Businesses conduct <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\"> to find the <\/span><span style=\"font-weight: 400;\">causal factors<\/span><span style=\"font-weight: 400;\"> behind their problems and eliminate them. Ultimately, <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\"> enables <\/span><a href=\"https:\/\/limblecmms.com\/blog\/proactive-maintenance\/\"><span style=\"font-weight: 400;\">proactive maintenance<\/span><\/a><span style=\"font-weight: 400;\"> and <a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/asset-lifecycle-management\/\">asset management<\/a>. Instead of correcting issues after they occur, you\u2019ll stop them from happening in the <\/span><span style=\"font-weight: 400;\">first place<\/span><span style=\"font-weight: 400;\">. <\/span><\/p>\n<h2><span style=\"font-weight: 400;\">How to conduct an effective root cause analysis in 4 steps<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">You can conduct <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> with the help of a range of different tools and techniques. Though these processes may look different, they all share a common goal: fixing the root cause of an issue. <\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">To do a <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> the right way, you should follow four basic steps:<\/span><\/p>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Define the problem<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Collect data<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Map out the events to <\/span><span style=\"font-weight: 400;\">identify root causes<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\">Implement solutions to solve the problem<\/li>\n<\/ol>\n<h3><b>Step 1: Define the problem\u00a0<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">By defining the problem, its symptoms, and its consequences, you\u2019ll set the scope and direction of the analysis.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Without a <\/span><span style=\"font-weight: 400;\">specific problem statement<\/span><span style=\"font-weight: 400;\">, you\u2019ll struggle to create a path to a solution. A well-defined <\/span><span style=\"font-weight: 400;\">problem statement<\/span><span style=\"font-weight: 400;\"> also helps determine the scale and scope of the solution you\u2019ll ultimately implement. When you\u2019re writing your <\/span><span style=\"font-weight: 400;\">problem statement<\/span><span style=\"font-weight: 400;\">, keep these three questions in mind:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">How would you describe the problem at hand?<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">What do you see happening?<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">What are the specific symptoms?<\/span><\/li>\n<\/ul>\n<h3><b>Step 2: Collect the data<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Next, <\/span><span style=\"font-weight: 400;\">gather data<\/span><span style=\"font-weight: 400;\"> related to your problem or incident. Record <\/span><i><span style=\"font-weight: 400;\">anything<\/span><\/i><span style=\"font-weight: 400;\"> that might help you get to the source of your organization\u2019s trouble.<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Take, for example, a machine failure in a manufacturing plant. You\u2019ll want to track data like:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The age of your equipment<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Your equipment\u2019s operational time<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Your equipment\u2019s operating patterns<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The typical maintenance schedule<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Characteristics of the operating environment<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The names of the operators who typically handle the machine<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The technical specifications of the machine<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Inspecting the machine in person provides plenty of information that could serve your <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\">. Facilities that run <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/predictive-maintenance\/\"><span style=\"font-weight: 400;\">predictive maintenance<\/span><\/a><span style=\"font-weight: 400;\"> need to take particular care to collate their data quickly. <\/span><\/p>\n<h3><b>Step 3: Map out the events<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Then, establish a timeline of events. This will help you determine which factors among the data collected are most worth investigating. Putting events and data in chronological order helps to differentiate <\/span><span style=\"font-weight: 400;\">causal factors<\/span><span style=\"font-weight: 400;\"> from non-<\/span><span style=\"font-weight: 400;\">causal factors<\/span><span style=\"font-weight: 400;\">.<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">From the data collected, you can identify correlations between various events, their timing, and other data collected. Remember that <\/span><a href=\"https:\/\/clevertap.com\/blog\/correlation-vs-causation\/\"><span style=\"font-weight: 400;\">correlation does not mean causation<\/span><\/a><span style=\"font-weight: 400;\">.\u00a0<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-3939 size-large\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-1024x551.jpg\" alt=\"causation vs correlation\" width=\"1024\" height=\"551\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-1024x551.jpg 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-300x162.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-768x413.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-442x238.jpg 442w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-542x292.jpg 542w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-93x50.jpg 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-540x291.jpg 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation-100x54.jpg 100w, https:\/\/limblecmms.com\/wp-content\/uploads\/causation-vs-correlation.jpg 1200w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Here\u2019s the difference between causation and correlation in a maintenance context.\u00a0<\/span><\/i><\/p>\n<p><span style=\"font-weight: 400;\">Questions to ask yourself when looking for correlations:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">What <\/span><span style=\"font-weight: 400;\">sequence of events<\/span><span style=\"font-weight: 400;\"> allowed this to happen?\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">What conditions allowed this to happen?\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">What additional problems result from the main problem?\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The next step is to employ additional <\/span><span style=\"font-weight: 400;\">root cause analysis tools<\/span><span style=\"font-weight: 400;\"> to identify <\/span><span style=\"font-weight: 400;\">potential causes<\/span><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">For example, you might map out events with the help of a <\/span><a href=\"https:\/\/towardsdatascience.com\/use-causal-graphs-4e3af630cf64\"><span style=\"font-weight: 400;\">causal graph<\/span><\/a><span style=\"font-weight: 400;\">. These graphs represent the relationship between the events that happened and the data you\u2019ve collected. The different paths are given different probability weights. They can serve as a visual tool to track down the root cause.<\/span><\/p>\n<h3><b>Step 4: Address the root of the problem<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Once you\u2019ve identified the root cause, you can quickly determine the best solution to fix it. Map the solution against the scope defined in your initial <\/span><span style=\"font-weight: 400;\">problem statement<\/span><span style=\"font-weight: 400;\">. Do you have the resources you need? If so, it\u2019s time to implement a solution.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Once the problem is solved, you will need to take <\/span><a href=\"https:\/\/limblecmms.com\/blog\/preventive-maintenance-benefits\/\"><span style=\"font-weight: 400;\">preventive steps<\/span><\/a><span style=\"font-weight: 400;\"> to ensure it doesn\u2019t happen again. If the symptoms occur again, it\u2019s time to return to the drawing board and conduct <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\"> again.<\/span><\/p>\n<h2>The 3 Rs of Performing Root Cause Analysis<\/h2>\n<p><span style=\"font-weight: 400;\">Another simple way of understanding <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> focuses on the 3 Rs of <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\">: recognize, rectify, replicate.\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Recognize<\/b><span style=\"font-weight: 400;\">: Taking <\/span><span style=\"font-weight: 400;\">corrective action<\/span><span style=\"font-weight: 400;\"> begins with identifying the problem. With a detailed <\/span><span style=\"font-weight: 400;\">problem statement<\/span><span style=\"font-weight: 400;\">, you\u2019ll have a dependable procedure for digging into the issue and finding the root cause.\u00a0\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Rectify<\/b><span style=\"font-weight: 400;\">: Once you\u2019ve identified the root cause, you can take measures to ensure it doesn\u2019t happen again. If it reappears, you may have addressed symptoms alone.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Replicate<\/b>: Attempting to recreate a problem helps you test whether you actually fixed the root issue. You might also try to replicate the conditions that led to a positive outcome.<\/li>\n<\/ul>\n<h2><b>Root cause analysis tools<\/b><b> and techniques<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">There are many tried and trusted frameworks for executing <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\">. Some offer a better fit for certain industries than for others or help to address specific types of problems.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Your company should establish its own unique <\/span><span style=\"font-weight: 400;\">methodology<\/span><span style=\"font-weight: 400;\"> for conducting <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\"> and always tailor its approach to the issue at hand. In some instances, you might bring in external consultants to guide your efforts or even execute the analysis. <\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">Let\u2019s look at some of the different forms of <\/span><span style=\"font-weight: 400;\">root cause analyses<\/span><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<h3><b>5 Why analysis<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The <\/span><span style=\"font-weight: 400;\">5 Whys<\/span><span style=\"font-weight: 400;\"> technique for <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> and <\/span><span style=\"font-weight: 400;\">problem solving<\/span><span style=\"font-weight: 400;\"> was developed by Sakichi Toyoda. It is at the heart of the Toyota Motor Company\u2019s <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/lean-manufacturing\/\"><span style=\"font-weight: 400;\">lean manufacturing processes<\/span><\/a><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Simply put, the process involves asking \u2018why\u2019 over and over again until you\u2019ve reached the <\/span><span style=\"font-weight: 400;\">root cause of a problem<\/span><span style=\"font-weight: 400;\">. The goal is to ask why until you can\u2019t anymore.<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">A rule of thumb holds that 5 \u2018whys\u2019 is usually enough.\u00a0<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-3941 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-1024x939.jpg\" alt=\"5 Why analysis\" width=\"500\" height=\"459\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-1024x939.jpg 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-300x275.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-768x704.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-260x238.jpg 260w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-319x292.jpg 319w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-65x60.jpg 65w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-442x405.jpg 442w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why-100x92.jpg 100w, https:\/\/limblecmms.com\/wp-content\/uploads\/5-why.jpg 1200w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">Asking \u2018why\u2019 brings businesses closer to the root cause of their problems.\u00a0<\/span><\/i><\/p>\n<p><b>Benefits of <\/b><b>5 Why<\/b><b> analysis<\/b><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Quickly identifies the <\/span><span style=\"font-weight: 400;\">root cause of a problem<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Illustrates how one process can cause a chain of problems<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Helps determine the relationship between different root causes<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">No need for complicated evaluation techniques<\/span><\/li>\n<\/ul>\n<p><b>When to use the <\/b><b>5 Whys<\/b><span style=\"font-weight: 400;\">:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">For simple to moderately complex problems<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When <\/span><span style=\"font-weight: 400;\">human error<\/span><span style=\"font-weight: 400;\"> has contributed to your problems<\/span><\/li>\n<\/ul>\n<h3><b>Fishbone diagram (a.k.a. Ishikawa diagram)<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The Ishikawa method for <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> emerged from quality control techniques employed in the Japanese shipbuilding industry by Kaoru Ishikawa. It results in a <\/span><span style=\"font-weight: 400;\">fishbone diagram<\/span><span style=\"font-weight: 400;\"> (named for its resemblance to a <\/span><span style=\"font-weight: 400;\">fish skeleton<\/span><span style=\"font-weight: 400;\">) that explores the various <\/span><span style=\"font-weight: 400;\">potential causes<\/span><span style=\"font-weight: 400;\"> of one key problem.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Typical <\/span><span style=\"font-weight: 400;\">fishbone diagrams<\/span><span style=\"font-weight: 400;\"> break causes into six categories, the six Ms:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Manpower (personnel)\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Machines<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Measurement<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Methods<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Materials<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Mother nature (environment)<\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-3942\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram.jpg\" alt=\"Fishbone digram (Iskikawa method)\" width=\"500\" height=\"308\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram.jpg 1200w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-300x185.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-1024x631.jpg 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-768x473.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-386x238.jpg 386w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-474x292.jpg 474w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-93x57.jpg 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-540x333.jpg 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/fishbone-diagram-100x62.jpg 100w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">An <\/span><\/i><i><span style=\"font-weight: 400;\">Ishikawa diagram<\/span><\/i><i><span style=\"font-weight: 400;\"> (also known as a <\/span><\/i><i><span style=\"font-weight: 400;\">fishbone diagram<\/span><\/i><i><span style=\"font-weight: 400;\">) outlines the various causes of a key business problem.\u00a0<\/span><\/i><\/p>\n<p><span style=\"font-weight: 400;\">Teams explore potential <\/span><span style=\"font-weight: 400;\">contributing factors<\/span><span style=\"font-weight: 400;\"> until they identify the <\/span><span style=\"font-weight: 400;\">root cause of the problem<\/span><span style=\"font-weight: 400;\">.<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">Benefits of <\/span><span style=\"font-weight: 400;\">fishbone diagrams<\/span><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Provides a useful structure to guide <\/span><span style=\"font-weight: 400;\">brainstorming<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Identifies potential bottlenecks<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Explores the full scope of <\/span><span style=\"font-weight: 400;\">potential causes<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">When to use a <\/span><span style=\"font-weight: 400;\">fishbone diagram<\/span><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">to analyze a complex problem with many <\/span><span style=\"font-weight: 400;\">potential causes<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">to identify bottlenecks and obstacles to process flow<\/span><\/li>\n<\/ul>\n<h2><b>Failure mode and effects analysis (FMEA)<\/b><\/h2>\n<p><a href=\"https:\/\/limblecmms.com\/blog\/fmea-and-fmeca\/\"><span style=\"font-weight: 400;\">FMEA<\/span> <\/a><span style=\"font-weight: 400;\">is a proactive approach to <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\">, preventing potential machine or system failures. It combines <\/span><a href=\"https:\/\/limblecmms.com\/blog\/reliability-engineering\/\"><span style=\"font-weight: 400;\">reliability engineering<\/span><\/a><span style=\"font-weight: 400;\">, safety engineering, and quality control efforts. The process involves predicting future failures and defects by analyzing data.\u00a0<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-3943\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA.png\" alt=\"FMEA\" width=\"1600\" height=\"599\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA.png 1600w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-300x112.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-1024x383.png 1024w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-768x288.png 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-1536x575.png 1536w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-451x169.png 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-554x207.png 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-93x35.png 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-540x202.png 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/FMEA-100x37.png 100w\" sizes=\"auto, (max-width: 1600px) 100vw, 1600px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">A diverse, cross-functional team is <\/span><a href=\"https:\/\/limblecmms.com\/blog\/fmea-and-fmeca\/\"><span style=\"font-weight: 400;\">essential for performing effective <\/span><span style=\"font-weight: 400;\">FMEA<\/span><\/a><span style=\"font-weight: 400;\">. Make sure to clearly define and communicate the scope of the analysis to your <\/span><span style=\"font-weight: 400;\">team members<\/span><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Your team will closely review each subsystem, design, and process to better understand their purposes and functions. Next, the seam should <\/span><span style=\"font-weight: 400;\">brainstorm<\/span><span style=\"font-weight: 400;\"> potential failure modes based on data and past experiences.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Then, the team can calculate the risk priority number (RPN) for each potential failure mode. The formula below shows how the severity, likelihood, and detectability of <\/span><span style=\"font-weight: 400;\">potential causes<\/span><span style=\"font-weight: 400;\"> contribute to its RPN.\u00a0<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-1843\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation.jpg\" alt=\"(RPN) risk priority number formula\" width=\"1000\" height=\"340\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation.jpg 1000w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-300x102.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-768x261.jpg 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-451x153.jpg 451w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-554x188.jpg 554w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-93x32.jpg 93w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-540x184.jpg 540w, https:\/\/limblecmms.com\/wp-content\/uploads\/RPN-calculation-100x34.jpg 100w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">If the failure mode has a higher RPN than you\u2019re comfortable with, you can begin planning out <\/span><span style=\"font-weight: 400;\">corrective actions<\/span><span style=\"font-weight: 400;\">. <\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><b>Benefits of <\/b><b>FMEA<\/b><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Enables your team to identify failure points early<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Takes advantage of your team\u2019s collective knowledge<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improves the quality, reliability, and safety of <\/span><span style=\"font-weight: 400;\">corrective actions<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Introduces a logical, structured approach for identifying process areas of concern<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Documents and tracks risk reduction activities<\/span><\/li>\n<\/ul>\n<p><b>When to use the <\/b><b>FMEA<\/b> <b>methodologies<\/b><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When you\u2019re designing new products, <\/span><span style=\"font-weight: 400;\">business processes<\/span><span style=\"font-weight: 400;\">, or service offerings (DFMEA)<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When you have a plan for quality improvement<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When you need to understand the failures in a <\/span><span style=\"font-weight: 400;\">business process<\/span><span style=\"font-weight: 400;\"> and improve upon them (PFMEA)<\/li>\n<\/ul>\n<h3><b>Fault tree analysis (FTA)<\/b><\/h3>\n<p><a href=\"https:\/\/limblecmms.com\/blog\/fault-tree-analysis\/\"><span style=\"font-weight: 400;\">Fault tree analysis<\/span><\/a><span style=\"font-weight: 400;\"> is an <\/span><span style=\"font-weight: 400;\">RCA process<\/span><span style=\"font-weight: 400;\"> that uses boolean logic to identify the cause of a fault or failure.The process involves mapping the logical relationships between faults and the subsystems of a machine.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">You <\/span><span style=\"font-weight: 400;\">first place<\/span><span style=\"font-weight: 400;\"> the failure you\u2019re analyzing at the top of the chart. If two causes have a logical <\/span><i><span style=\"font-weight: 400;\">or<\/span><\/i><span style=\"font-weight: 400;\"> combination causing effect, they are combined with a logical <\/span><i><span style=\"font-weight: 400;\">or<\/span><\/i><span style=\"font-weight: 400;\"> operator. For example, if a machine can fail while in operation or while under maintenance, it is a logical <\/span><i><span style=\"font-weight: 400;\">or<\/span><\/i><span style=\"font-weight: 400;\"> relationship.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-3945\" style=\"border: black; border-width: 3px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example.png\" alt=\"Fault tree analysis example\" width=\"500\" height=\"396\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example.png 615w, https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example-300x238.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example-301x238.png 301w, https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example-369x292.png 369w, https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example-76x60.png 76w, https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example-511x405.png 511w, https:\/\/limblecmms.com\/wp-content\/uploads\/Fault-tree-analysis-example-100x79.png 100w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">An example of a <\/span><\/i><i><span style=\"font-weight: 400;\">fault tree analysis<\/span><\/i> <a href=\"https:\/\/sixsigmastudyguide.com\/fault-tree-analysis\/\"><span style=\"font-weight: 400;\">Source: <\/span><span style=\"font-weight: 400;\">Six Sigma<\/span><span style=\"font-weight: 400;\"> Study Guide<\/span><\/a><\/p>\n<p><span style=\"font-weight: 400;\">If two causes need to occur simultaneously for the fault to happen, the situation is represented with a logical <\/span><i><span style=\"font-weight: 400;\">and<\/span><\/i><span style=\"font-weight: 400;\">. For example, if a machine only fails when the operator pushes the wrong button <\/span><i><span style=\"font-weight: 400;\">and<\/span><\/i><span style=\"font-weight: 400;\"> relay fails to activate, it is a logical <\/span><i><span style=\"font-weight: 400;\">and<\/span><\/i><span style=\"font-weight: 400;\"> relationship.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Your team can then analyze the fault tree to identify <\/span><span style=\"font-weight: 400;\">process improvements<\/span><span style=\"font-weight: 400;\"> and <\/span><span style=\"font-weight: 400;\">risk management<\/span><span style=\"font-weight: 400;\"> opportunities. It\u2019s an especially effective tool for analyzing automated machines and systems. In the above example, <\/span><i><span style=\"font-weight: 400;\">and <\/span><\/i><span style=\"font-weight: 400;\">is in blue and <\/span><i><span style=\"font-weight: 400;\">or<\/span><\/i><span style=\"font-weight: 400;\"> is in purple.\u00a0 <\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><b>Benefits of using a <\/b><b>fault tree analysis<\/b><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Deduces the cause of events<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Highlights the critical elements related to system failure<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Creates a visual representation to simplify failure analysis<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Accounts for <\/span><span style=\"font-weight: 400;\">human error<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Promotes effective communication between <\/span><span style=\"font-weight: 400;\">team members<\/span><\/li>\n<\/ul>\n<p><b>When to use a <\/b><b>fault tree analysis<\/b><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When you need to determined if a combination of <\/span><span style=\"font-weight: 400;\">contributing factors<\/span><span style=\"font-weight: 400;\"> is causing a problem<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">When you are designing a solution and need to identify potential sources of failure to make the solution more robust\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">To find issues that can cause <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/fault-tolerance\/\"><span style=\"font-weight: 400;\">fault-tolerant systems<\/span><\/a><span style=\"font-weight: 400;\"> to experience total failure<\/span><\/p>\n<h3><b>Pareto charts<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">A <\/span><span style=\"font-weight: 400;\">Pareto chart<\/span><span style=\"font-weight: 400;\"> indicates the frequency of defects and their cumulative effects. Italian economist Vilfredo Pareto recognized a common theme across all the frequency distributions he could observe. He noticed a vast imbalance between the ratio of failures and the effects caused by them. <\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">In any system, he proposed that 80% of the results (or failures) are caused by 20% of all <\/span><span style=\"font-weight: 400;\">potential causes<\/span><span style=\"font-weight: 400;\">. This concept is known as the Pareto principle or the 80-20 rule.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">With the 80-20 principle in mind, you can use Pareto analysis to dig into failures and their <\/span><span style=\"font-weight: 400;\">possible causes<\/span><span style=\"font-weight: 400;\">. To start, draw a bar graph that includes the frequency of faults and causes. This graph will make it much easier to see the skewed relationship between causes and effects. <\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">Next, you\u2019ll analyze the causes that contribute to the largest number of faults and take <\/span><span style=\"font-weight: 400;\">corrective action<\/span><span style=\"font-weight: 400;\"> to eliminate the most common defects.<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><b>Benefits of using <\/b><b>pareto charts<\/b><span style=\"font-weight: 400;\">:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Defects are ranked in order of severity, making it simple to organize priorities<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Helps cumulative the cumulative impact of defects<\/span><\/li>\n<\/ul>\n<p><b>When to use a <\/b><b>pareto chart<\/b><b>:<\/b><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">To narrow down a list of problems and find the most significant<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">To analyze a problem with a broad list of causes and identify specific components<\/span><\/li>\n<\/ul>\n<h2>More root cause analysis methods and tools<\/h2>\n<p><span style=\"font-weight: 400;\">The <\/span><span style=\"font-weight: 400;\">root cause analysis process<\/span><span style=\"font-weight: 400;\"> looks different for different organizations and varies based on the problem you\u2019re addressing. Here are some additional approaches:\u00a0\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Cause and effect diagrams<\/span><span style=\"font-weight: 400;\"> try to map the relationship between causes and effects in a system.\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Barrier analysis is an <\/span><span style=\"font-weight: 400;\">RCA<\/span><span style=\"font-weight: 400;\"> technique commonly used for safety incidents. It is based on the idea that a barrier between personnel and potential hazards can prevent most safety incidents.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Change analysis<\/span><span style=\"font-weight: 400;\"> is used when a potential incident occurs due to a single element or factor change.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">A scatter diagram is a statistical tool that plots the relationship between two data points in a two-dimensional chart.\u00a0<\/span><\/li>\n<\/ul>\n<p>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<\/p>\n<h2>Get started with maintenance management software<\/h2>\n<p><span style=\"font-weight: 400;\">If you\u2019re feeling overwhelmed, don\u2019t worry. Whether you\u2019re conducting a <\/span><span style=\"font-weight: 400;\">root cause analysis<\/span><span style=\"font-weight: 400;\"> for the first time or looking to refine your existing processes, Limble\u2019s computerized maintenance management solution (CMMS) can help. By enabling maintenance teams to say goodbye to pen, paper, and spreadsheets, it simplifies every aspect of asset management.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">If you want to learn more about how Limble could make your job less stressful, get started with a <\/span><a href=\"https:\/\/limblecmms.com\/pricing\/\"><span style=\"font-weight: 400;\">free trial<\/span><\/a><span style=\"font-weight: 400;\"> or <\/span><a href=\"https:\/\/limblecmms.com\/\"><span style=\"font-weight: 400;\">set up a demo<\/span><\/a><span style=\"font-weight: 400;\"> today.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_column][\/vc_column]<br \/>\n[vc_row content_placement=&#8221;middle&#8221; css_animation=&#8221;fadeInDown&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1699310630716{margin-top: 30px !important;margin-bottom: 50px !important;padding-top: 50px !important;padding-bottom: 50px !important;background-color: #dde4e8 !important;border-radius: 20px !important;}&#8221;][vc_column width=&#8221;2\/3&#8243; css=&#8221;.vc_custom_1699310302582{padding-left: 25px !important;}&#8221;]<header class=\"kd-section-title col-lg-12 text-left  subtitle-below-title    vc_custom_1711111410967\" ><h3 class=\"separator_off\" >Download our Free CMMS Buyer's Guide!<\/h3><p class=\"subtitle\" >Learn the questions to ask and the features to look for during the CMMS selection process - and find the right CMMS for you.<\/p><\/header><a  href=\"https:\/\/limblecmms.com\/resources\/cmms-buyers-guide\/\"  target=\"_self\"  title=\"Download Now\"  class=\"tt_button tt_primary_button btn_primary_color  button-center button-action-link icon_right\" ><span class=\"prim_text\">Get the Guide<\/span><span class=\"fas fa-angle-right iconita\" ><\/span><\/a>[\/vc_column][vc_column width=&#8221;1\/3&#8243;][vc_single_image source=&#8221;external_link&#8221; external_img_size=&#8221;219&#215;300&#8243; css=&#8221;.vc_custom_1711111608728{padding-bottom: 10px !important;}&#8221; custom_src=&#8221;https:\/\/3975608.fs1.hubspotusercontent-na1.net\/hubfs\/3975608\/Content%20Downloads\/CMMS%20Buyers%20Guide%20Image.png&#8221;][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]Conducting a root cause analysis (RCA) helps trace recurring [&hellip;]<\/p>\n","protected":false},"author":24,"featured_media":29400,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[740],"tags":[],"class_list":["post-3937","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-metrics"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) - 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