The root of an effective root cause analysis

Abstract

Manufacturing process variations can remain unsolved despite repeated problemsolving efforts, even though a large variety of root cause analysis tools are well known. This study investigates the practical challenges and opportunities that influence the efficiency of root cause analysis in complex manufacturing contexts. Using an action research approach, a longstanding manufacturing instability related to windshield adhesive at a knock-down truck assembly plant was analyzed through the Six Sigma DMAIC framework. Throughout the study barriers and enablers were identified on both previous problemsolving attempts and the newly conducted root cause analysis. 30 barriers and 20 enablers were identified and categorized. The findings demonstrate that problemsolving tools and methods alone are not sufficient. Effective root cause analysis requires a fact based approach, supported by high-quality and accessible data, strong communication and collaboration, clearly defined roles and responsibilities, ownership of the problem, clear standardized procedures, and management commitment. A conceptual model was developed to illustrate the interrelations between these factors within the organizational system. The study concludes that effective root cause analysis depends not solely on the method, but on the organizational system that shapes how issues are framed, understood and addressed.