Identification and Assessment of Cost and Effort Criteria for Prioritisation during Root Cause Analysis
Abstract
Purpose: This study sought to provide a matrix by which to prioritise hypotheses in an Ishikawa diagram while considering a combination of the hypotheses' relation to the problem and the cost and effort to investigate because potential failure causes in an Ishikawa diagram are often prioritised for investigation using subjective methods, and not concrete criteria.
Methodology/Approach: A survey was sent to organisations seeking to determine three levels of prioritisation for effort in hours to investigate a problem and costs to investigate. The results were then entered into a matrix that listed three levels of relationship between the hypothesis and the problem as well as three levels of costs and effort. A scenario was given to study participants in the industry to determine if participants with the hypothesis prioritisation matrix could find the correct hypotheses to investigate first, more often than participants without the matrix.
Findings: The survey resulted in criteria for prioritisation of hypotheses to investigate. A study with employees in the industry found that participants with a hypothesis prioritisation matrix identified the correct hypotheses to investigate first more often than participants without the matrix.
Research Limitation/implication: This paper provides concrete criteria for prioritising hypotheses to investigate during a root cause analysis.
Originality/Value of paper: This paper provides concrete criteria for prioritising hypotheses.
Full text article
References
Al-Hyari, K.A., Abu Zaid, M.K., Arabeyyat, O.S., Al-Qwasmeh, L. and Haffar, M., 2019. The Applications of Kaizen Methods in Project Settings: Applied Study in Jordan, The TQM Journal. 31(5), pp. 831-849. https://doi.org/10.1108/TQM-03-2019-0078.
Antony, J., McDermott, Sony, O.M., Fernandes, M. M. and Ribeiro, R.V.C., 2021. A Study on the Ishikawa's Original Basic Tools of Quality Control in South American Companies: Results from a Pilot Survey and Directions for Further Research, The TQM Journal, 33(8), pp. 1770-1786. https://doi.org/10.1108/TQM-01-2021-0004.
Araman, H. and Saleh, Y., 2023. A Case Study on Implementing Lean Six Sigma: DMAIC Methodology in Aluminum Profiles Extrusion Process, The TQM Journal, 35(2), pp. 337-365. https://doi.org/10.1108/TQM-05-2021-0154.
Barsalou, M. and Smith, J., 2018. Applied Statistics Manual: A Guide to Improving and Sustaining Quality with Minitab. Milwaukee, WI: Quality Press.
Barsalou, M., 2022. Criteria for the Prioritisation of Hypotheses in Root Cause Analysis, Quality and Reliability Engineering International, 39(1), pp. 132-142. https://doi.org/10.1002/qre.3224.
Barsalou, M., 2023. Case Study in Hypothesis Prioritisation with Ishikawa Diagrams, Management Systems in Production Engineering, 31(4), pp. 381-388. https://doi.org/10.2478/mspe-2023-0042.
Chapman, P., Bernon, M., Haggett, P., 2011. Applying Selected Quality Management Techniques to Diagnose Delivery Time Variability, International Journal of Quality and Reliability Management, 28(9), pp. 1019-1040. https://doi.org/10.1108/02656711111172568.
Doshi, J.A., Kamdar, J.D., Jani, S.Y., and Chaidhary, S.J., 2012. Root Cause Analysis Using Ishikawa Diagram For Reducing Radiator Rejection, Engineering Research and Applications, 2(6) pp. 684-689.
Dziuba, S.T., Jarossová, M.A., and Gołębiecka, N., 2014. Applying the 5 Why Method to Verification of Non-Compliance Causes Established After Application of the Ishikawa Diagram in the Process of Improving the Production of Drive Half-Shafts, Production Engineering Archive, 2(1), pp. 16-19. https://doi.org/0.30657/pea.2014.02.05.
Germanova‐Krasteva, D. and Petrov, H., 2008. Investigation on the Seam's Quality by Sewing of Light Fabrics, International Journal of Clothing Science and Technology, 20(1), pp. 57-64. https://doi.org/10.1108/09556220810843539.
George, A., Ranjha, S., and Kulkarni, A., 2021. Enhanced Problem Solving Through Redefined 8D Step Completion Criteria, Quality Engineering, 33(4), pp. 695-711. https://doi.org/10.1080/08982112.2021.1969665.
Gryna, F.M., 2001. Quality Planning and Analysis (4th ed.). New York, NY: McGraw-Hill.
Hirsch, V., Reimann, P., Mitschang, B., 2020. Incorporating Economic Aspects into Recommendation Ranking to Reduce Failure Costs, Procedia CIRP, 93, pp. 747-752. https://doi.org/10.1016/j.procir.2020.03.026.
Jayaprasad, G., Dhanlakshmi, P.P., and Hemachandran, S., 2016. Analysis of Electrical Discontinuity Problem in MLB using Ishikawa Model, Circuit World. 42(4), pp. 201-206. https://doi.org/10.1108/CW-08-2016-0036.
Laman, S.A. (ed.)., 2022. The ASQ Certified Quality Engineer, Milwaukee, WI: Quality Press.
Mahanti, R., 2014. Application of Quality Tools to Data Warehousing Projects, Software Quality Professional, 16(4), pp. 26-35.
McDermott, O., Antony, J., Sony, M., Rosa, A., Hickey, M., and Grant, T.A., 2023a. 'A Study on Ishikawa's Original Basic Tools of Quality' Control in Healthcare, The TQM Journal, 35(7), pp. 1686-1705. https://doi.org/10.1108/TQM-06-2022-0187 .
McDermott, O., Antony, J., Sony, M., Fernandes, M.M., Koul, R., and Doulatabadi, M., 2023b. The use and Application of the 7 New Quality Control Tools in the Manufacturing Sector: A Global Study, The TQM Journal, 35(8), pp. 2621-2639. https://doi.org/10.1108/TQM-06-2022-0186.
McShane-Vaughn, M. 2016. The Probability Handbook. Milwaukee, WI: Quality Press.
Pyzdek, T. and Maciulla, J.A., 1995. A Chronicle of a Quality Improvement Project, Quality Engineering, 7(3), pp. 471-479. https://doi.org/10.1080/08982119508918798.
Rodchua, S., 2009. Comparative Analysis of Quality Costs and Organization Sizes in the Manufacturing Environment, Quality Management Journal, 16(2), pp. 34-43. https://doi.org/10.1080/10686967.2009.11918225.
Sarkar, S.A., Mukhopadhyay, A.R., Ghosh, S.K., 2013. Root Cause Analysis, Lean Six Sigma and Test of Hypothesis, The TQM Journal, 25(2), pp. 170-185. https://doi.org/10.1108/17542731311299609.
Shamsuzzaman, M., Khadem, M., Haridy, S., Shamsuzzoha, A., Abdalla, M., M. Al-Hanini, M., Almheiri, H., and Masadeh, O., 2023. Improving the Admission Process in a Higher Education Institute Using Lean Six Sigma: A Case Study, International Journal of Lean Six Sigma, 14(7), pp. 1596-1625. https://doi.org/10.1108/IJLSS-05-2021-0098.
Shang, L., Qiu, Q., Wu, C., and Du, Y., 2022. Random Replacement Policies to Sustain the Post-Warranty Reliability, Journal of Quality in Maintenance Engineering, 29(2), pp. 481-508. https://doi.org/10.1108/JQME-09-2021-0067.
Sharma, R.K., Kumar, D., and Sharma, P., 2010. System Failure Behavior and Maintenance Decision Making Using, RCA, FMEA and FM, Journal of Quality in Maintenance Engineering, 16(1), pp. 64-88. https://doi.org//10.1108/13552511011030336.
Smith, G.F., 1998. Determining the Cause of Quality Problems: Lessons from Diagnostic Disciplines, Quality Management Journal, 5(2), pp. 24-40. https://doi.org/10.1080/10686967.1998.11918852.
Solanki, M. and Desai, D., 2021. Competitive Advantage Through Six Sigma in Sand Casting Industry to Improve Overall First-pass Yield: A Case Study of SSE, International Journal of Lean Six Sigma, 12(3), pp. 477-502. https://doi.org/10.1108/IJLSS-03-2020-0032.
Srivastava, S., Satsangi, K., and Satsangee, N., 2019. Identification of Entrepreneurial Education Contents using Nominal Group Technique, Education + Training, 61(7/8), pp. 101-1019. https://doi.org/10.1108/ET-05-2018-0105.
Trakulsunti, Y., Antony, J., Dempsey, M., and Brennan, A., 2021. Reducing Medication Errors using Lean Six Sigma Methodology in a Thai Hospital: An Action Research Study, International Journal of Quality and Reliability Management, 38(1), 339-362. https://doi.org/10.1108/IJQRM-10-2019-0334.
Trakulsunti, Y., Antony, R. Edgeman, R., Cudney, B., Dempsey, M., and Brennan, A., 2022. Reducing Pharmacy Medication Errors using Lean Six Sigma: A Thai Hospital Case Study, Total Quality Management and Business Excellence, 33(5-6), pp. 664-682. https://doi.org/10.1080/14783363.2021.1885292.
Uluskan, M., 2017. Analysis of Lean Six Sigma Tools from a Multidimensional Perspective, Total Quality Management and Business Excellence, 30(9), pp. 1167-1188. https://doi.org/10.1080/14783363.2017.1360134
Uluskan, U. and Oda, E. P., 2020. A Thorough Six Sigma DMAIC Application for Household Appliance Manufacturing Systems, The TQM Journal, 32(6), pp. 1683-1714. https://doi.org/10.1108/TQM-06-2019-0171.
Yadav, N., Mathiyazhagan, K., and Kumar, K., 2019. Application of Six Sigma to Minimise the Defects in Glass Manufacturing Industry: A Case Study, Journal of Advances in Management Research, 16(4), pp. 594-624. https://doi.org/10.1108/JAMR-11-2018-0102.
Authors
Copyright (c) 2024 Matthew Barsalou, Beata Starzyńska, Maria Konrad, André Carvalho, Rogério Puga-Leal
This work is licensed under a Creative Commons Attribution 4.0 International License.
This is an open access journal which means that all content is freely available without charge to the user or his/her institution. Users are allowed to read, download, copy, distribute, print, search, or link to the full texts of the articles in this journal without asking prior permission from the publisher or the author. This is in accordance with the BOAI definition of open access. This journal is licensed under a Creative Commons Attribution 4.0 License - http://creativecommons.org/licenses/by/4.0.
Authors who publish with the Quality Innovation Prosperity agree to the following terms:
- Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work.