Root cause analysis (RCA) is an essential part of any AS9100 quality management system. It is a systematic approach to identifying the underlying causes of problems. It is a key tool used in AS9100.
In AS9100, RCA is required for a variety of situations, including:
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When a customer complaint is received
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When a non-conformance is found during production or testing
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When an accident or incident occurs
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When there is a significant change to the product or process
RCA is important for AS9100 because it helps organizations to:
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Identify the root cause of problems, so that they can be prevented from recurring
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Improve the quality of their products and services
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Increase customer satisfaction
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Reduce costs
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Improve safety
Within Root Cause Analysis there is a proven method that helps quality managers with their systems. It’s called the 8D methodology.
The Eight steps in the 8D methodology of Root Cause Analysis
The 8D methodology consists of eight steps:
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Define the problem. The first step is to clearly define the problem that needs to be solved. This may involve gathering data, such as customer complaints, test results, or production data.
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Form a team. The 8D process should be carried out by a team of people who have knowledge of the problem area. The team should include representatives from all levels of the organization, as well as from different functional areas.
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Do a quick fix. This step is optional, but it can be helpful to implement a quick fix to stop the problem from recurring while the team is investigating the root cause.
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Determine the root cause. The team should use a variety of tools, such as brainstorming, cause-and-effect diagrams, and 5 Whys, to identify the root cause of the problem.
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Develop corrective actions. Once the root cause has been identified, the team can develop corrective actions to address it. The corrective actions should be specific, measurable, achievable, relevant, and time-bound.
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Implement corrective actions. The corrective actions should be implemented in a timely manner. The team should monitor the results of the corrective actions to ensure that they are effective.
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Prevent recurrence. The team should take steps to prevent the problem from recurring. This may involve implementing new procedures, training, or changes to the product or process.
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Celebrate success. Once the problem has been solved, the team should celebrate their success. This will help to motivate the team and encourage them to continue to solve problems.
The 8D methodology is a valuable tool for quality managers who want to improve the quality of their products and services. By following the above steps, quality managers can identify and address problems effectively.
Here are some additional tips for using the 8D methodology:
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Be objective. The 8D team should be objective and avoid blaming individuals or departments.
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Focus on the root cause. The goal of 8D is to identify the root cause of the problem, not just the symptoms.
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Get input from all levels. The 8D team should get input from all levels of the organization, as different people may have different perspectives on the problem.
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Use data to support your conclusions. The 8D team should use data to support its conclusions. This data can be gathered from a variety of sources, such as customer complaints, test results, or production data.
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Follow up. The 8D team should follow up to ensure that the corrective actions are implemented and effective.
Why a quality manager should be trained on root cause analysis in AS9100
AS9100 requires organizations to have a process for identifying and addressing problems. RCA is a key tool for within the AS9100 standard and its process which in return help quality managers to improve their communication and problem-solving skills. Becoming trained within the 8D methodology gives quality managers credibility with their colleagues and customers.
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