Root Cause Analysis (RCA) is a structured, evidence-based method used to identify, verify, and document the underlying causes of observed problems such as defects, equipment failures, process deviations, or safety incidents.
In a manufacturing context, RCA typically follows a defined sequence of activities:
- Problem definition: Clearly describing the problem, its scope, impact, and boundaries.
- Data collection: Gathering factual information, records, process data, and observations related to the event.
- Process mapping: Documenting the relevant process steps, inputs, outputs, and interfaces to understand where and how the issue occurs.
- Cause analysis: Using structured tools (for example, fishbone diagrams, 5 Whys, fault tree analysis) to identify potential causal factors.
- Root cause verification: Testing and confirming which causes are necessary and sufficient to produce the problem, based on evidence.
- Corrective actions: Defining and implementing specific measures that address confirmed root causes.
- Validation and control: Checking whether the problem is resolved and establishing controls, standards, or monitoring to detect or prevent recurrence.
RCA is typically performed by people familiar with the process under review, uses documented data rather than assumptions where possible, and results in a traceable record of the analysis, decisions, and actions taken.