Step 4: Analyze the Root Causes

Points of Cause Revisited

In a previous module we learned about points of cause which describe where the problem is
happening within the process. Put another way, points of cause are the places the problem becomes
visible while the root causes are the things that cause them.

One way to think about this is to imagine a large tree. The part of the tree we can see above the
ground is the point of cause while the roots, under the ground, could be likened to the root cause.

And taken even one step beyond this these roots began to grow after some type of seed was placed
into the ground and encouraged to grow by water and the right environment.

Methods to Analyze Root Causes

With this said, let’s turn our attention towards some powerful methods anyone can use in order to
analyze and identify root causes. In subsequent modules we’ll take a deeper dive into several of
these methods explaining exactly what they are and how to
leverage them to your advantage.

The first, and arguably most important, concept we’d like to

share is to go see for yourself without prejudice.

In other words, we must go to gemba, or the place the work is

done, with an open mind as we work to identify what’s at the
root of the issues.

Next, while Pareto analysis helps us identify points of cause as we learned about in an earlier
module… it can also help us identify root causes in much the same way.

The third method I’d like to share is something we’ve heard about in previous modules as well as
previous Gemba Academy courses… and that concept is 5 why analysis.

We’ll focus in on 5 why in a future module but one of the key points I’d like to make here is that we
must work to drill down with 5 why on the same point of cause. In other words, we don’t want to
ask 5 whys on separate issues… instead we want to drill down on the same point of cause.

The next technique we can use to help identify root causes is called 4M+2 where we basically work
to identify potential root causes across 6 different categories.

1. The first M stands for man or can also be referred to as person. It is used to help identify
potential root causes associated with things like shift to shift variation as well as the physical
ability of associates.
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 2. The second M stands for material where potential root causes associated with things like
dimensional issues and overall material quality are investigated.
3. The third M stands for machine. Here we focus on potential root causes associated with
things like equipment condition and the settings used to operate the equipment.
4. The fourth M stands for method where things like work instructions, or the lack thereof, as
well as the way jobs are performed are investigated as potential root causes.
5. The fifth M stands for Mother Nature. Here potential root causes associated with things
such as temperature and humidity are investigated. Depending on where your company is
located this M can play a major role depending on the time of year.
6. The final M stands for measurement. Here potential root causes associated with the
capability or perhaps even the proper usage of measurement equipment is focused in on.

Now, in order to help facilitate the 4M+2 investigative process we can use a powerful tool called the
fishbone diagram.

The diagram above is what a fishbone diagram looks like… as you can see in this example the main
bones of the fish are made of the 4Ms. Then, smaller bones are added to these main bones as
potential root causes are identified.

For example, we see that burrs, misalignment, vibration, and friction are all potential problems
associated with the machine in question. To be sure there are many way to complete fishbone
diagrams and we’ll explore these in the next module. For now we just wanted to introduce you to
the tool.

We’ll be learning more about both 5 Why and the fishbone diagram in future modules.

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