Root Cause Analysis
Reproduced by kind permission of Gene Bellinger, OutSights [http://www.outsights.com]
This article appeared on a website and shows two ways to look at the same problem. Scenario 2
using root cause analysis.
Scenario # 1
The Plant Manager walked into the pant and found oil on the floor. He called the Foreman over and
told him to have maintenance clean up the oil. The next day while the Plant Manager was in the
same area of the plant he found oil on the floor again and he subsequently raked the Foreman over
the coals for not following his directions from the day before. His parting words were to either get
the oil cleaned up or he'd find someone that would.
Scenario # 2
The Plant Manager walked into the plant and found oil on the floor. He called the Foreman over and
asked him why there was oil on the floor. The Foreman indicated that it was due to a leaky gasket
in the pipe joint above. The Plant Manager then asked when the gasket had been replaced and the
Foreman responded that Maintenance had installed 4 gaskets over the past few weeks and they
each one seemed to leak. The Foreman also indicated that Maintenance had been talking to
Purchasing about the gaskets because it seemed they were all bad. The Plant Manager then went
to talk with Purchasing about the situation with the gaskets. The Purchasing Manager indicated
that they had in fact received a bad batch of gaskets from the supplier. The Purchasing Manager
also indicated that they had been trying for the past 2 months to try to get the supplier to make
good on the last order of 5,000 gaskets that all seemed to be bad. The Plant Manager then asked
the Purchasing Manager why they had purchased from this supplier if they were so disreputable
and the Purchasing Manager said because they were the lowest bidder when quotes were received
from various suppliers. The Plant Manager then asked the Purchasing Manager why they went with
the lowest bidder and he indicated that was the direction he had received from the VP of Finance.
The Plant Manager then went to talk to the VP of Finance about the situation. When the Plant
Manager asked the VP of Finance why Purchasing had been directed to always take the lowest
bidder the VP of Finance said, "Because you indicated that we had to be as cost conscious as
possible!" and purchasing from the lowest bidder saves us lots of money. The Plant Manger was
horrified when he realized that he was the reason there was oil on the plant floor. Bingo!
You may find scenario # 2 somewhat funny, and laugh at the situation. It would be better if the
situation made you weep because it is often all so true in numerous variations on the same theme.
Everyone in the organization doing their best to do the right things, and everything ends up messed
up. The root cause of this whole situation is local optimisation with no global thought involved.
Scenario # 2 also provides a good example of how one should proceed to do root cause analysis.
One simply has to continue to ask "Why?" until the pattern completes and the cause of the
difficulty in the situation becomes rather obvious.