๐’๐ฎ๐ง๐๐š๐ฒ'๐ฌ ๐“๐‡๐Ž๐”๐†๐‡๐“๐…๐”๐‹ ๐๐จ๐ฌ๐ญ : ๐‘๐จ๐จ๐ญ ๐‚๐š๐ฎ๐ฌ๐ž ๐€๐ง๐š๐ฅ๐ฒ๐ฌ๐ข๐ฌ (๐‘๐‚๐€) – ๐ƒ๐จ๐ง'๐ญ ๐…๐ข๐ฑ ๐ญ๐ก๐ž ๐’๐ฒ๐ฆ๐ฉ๐ญ๐จ๐ฆ, ๐…๐ข๐ฑ ๐ญ๐ก๐ž ๐๐ซ๐จ๐œ๐ž๐ฌ๐ฌ!

 ๐’๐ฎ๐ง๐๐š๐ฒ'๐ฌ ๐“๐‡๐Ž๐”๐†๐‡๐“๐…๐”๐‹ ๐๐จ๐ฌ๐ญ

๐Ÿ” ๐‘๐จ๐จ๐ญ ๐‚๐š๐ฎ๐ฌ๐ž ๐€๐ง๐š๐ฅ๐ฒ๐ฌ๐ข๐ฌ (๐‘๐‚๐€) – ๐ƒ๐จ๐ง'๐ญ ๐…๐ข๐ฑ ๐ญ๐ก๐ž ๐’๐ฒ๐ฆ๐ฉ๐ญ๐จ๐ฆ, ๐…๐ข๐ฑ ๐ญ๐ก๐ž ๐๐ซ๐จ๐œ๐ž๐ฌ๐ฌ! ⚙️

A broken tap is not the root cause—it's only the symptom. Effective RCA digs deeper to eliminate the real reason behind the failure.



๐Ÿ“Œ RCA Case Study: Tap Breakage During M8 Tapping


๐Ÿšจ Problem:

Tap broke during the tapping operation, causing production stoppage and rework.


๐Ÿ”Ž RCA Approach


✅ 5 Why Analysis

Identified that the actual root cause was:

➡️ No standardized verification process after tool replacement.


✅ Fishbone (Ishikawa) Diagram

Analyzed possible causes under:

๐Ÿ‘จ People

⚙️ Machine

๐Ÿ“‹ Method

๐Ÿงช Material

๐Ÿ“ Measurement

๐ŸŒก️ Environment


✅ Pareto Analysis

Focused on the few critical causes responsible for most tap breakage incidents.


๐Ÿ› ️ Corrective Actions (CA)


✔️ First-piece approval made mandatory

✔️ Standardized tapping parameters

✔️ Tool life monitoring introduced

✔️ Daily coolant concentration checks

✔️ Operator training completed

✔️ Layered Process Audits (LPA) implemented


๐Ÿ›ก️ Preventive Actions (PA)


✅ Poka-Yoke for program selection

✅ Updated Control Plan

✅ Revised PFMEA (RPN reduced)

✅ Weekly process compliance audits

✅ Visual parameter charts at the machine


๐ŸŽฏ Key Learning


๐Ÿ’ก Replacing the broken tool solves today's problem.

๐Ÿ’ก Improving the process prevents tomorrow's problem.


๐Ÿš€ Strong RCA leads to stronger processes, fewer defects, and sustainable quality improvement.


source : Six Sigma Manufacturing


#quality #qualityassurance #qualitycontrol #qualitymanagementsystem

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