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Relentless Root Cause Analysis: Process Overview Problem Solving or Firefighting? How do we stop Firefighting? Don’t tackle a problem unless you are committed to understanding its root cause and finding a valid solution Solve classes of problems, not just individual problems Don’t push to meet deadlines at all costs Train your problem solvers Don’t reward firefighting Don’t tolerate patching Pareto problems Develop and apply a systematic approach to problem solving… LEVELS OF ACE Relentless Root Cause Analysis Through A Disciplined Approach… Relentless Root Cause Analysis Through A Disciplined Approach… Define Purpose: Turn problem into well-defined and prioritized project(s). Leadership sponsors. Outcomes: Pareto of baseline data. Focus Tree with rationale for decision making. Project Charter (Problem Project Statements). Process: Define Impact and Goals Define Impact and Goals Prioritize and Select Project Prioritize and Select Project: Focus Tree Basic Components Problem Statement: description of an overarching problem containing a business metric. Ex. Scrap on PW2000 15/16th Stage Stators is running at $100K+ per month. Project Statement: description of a specific task from a process owner containing a measurable characteristic. Ex. Establish 100% line coverage in PW2000 15/16th stage HPC stator to eliminate $30K/month problem. Prioritize and Select Project: Focus Tree Construct Prioritize and Select Project: Focus Tree Example Prioritize and Select Project: Focus Tree Example Define Summary Investigate Purpose: Systematically eliminate inputs to converge on the root cause Outcomes: Investigation strategy Validated measurement system Root Cause Analysis Tree with rationale for decisions Process: Develop Strategy Generate Analyze Clues: Pareto Drives It All Generate Analyze Clues: Y-to-X Thinking Generate Analyze Clues: Attributes-to-Variables Data Generate Analyze Clues: Designed Experiments Generate Analyze Clues: Measurement System An