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RCA (Root Cause Analysis)

Root Cause Analysis (RCA) is a systematic process aimed at identifying the root causes of problems to prevent their recurrence. The process involves steps such as identifying the problem, gathering data, analyzing causes, and implementing corrective actions. Tools like the 5 Whys and Fishbone Diagram are utilized to facilitate the analysis and ensure effective solutions.

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21 views18 pages

RCA (Root Cause Analysis)

Root Cause Analysis (RCA) is a systematic process aimed at identifying the root causes of problems to prevent their recurrence. The process involves steps such as identifying the problem, gathering data, analyzing causes, and implementing corrective actions. Tools like the 5 Whys and Fishbone Diagram are utilized to facilitate the analysis and ensure effective solutions.

Uploaded by

ra.ajaygowda
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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What is

RCA
(Root Cause Analysis)

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
RCA
is a systematic process to identify
the root causes of problems to
prevent their recurrence.

For example
Why did a batch fail quality testing?
RCA finds the ‘why.’

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
RCA
Process
Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Steps
1.Identify the problem: Define the
issue (e.g., contamination in
production).
2. Gather data: Collect production
logs, test results and incident
reports.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Steps
3. Analyze causes: Use tools like
the 5 Whys or Fishbone Diagram.
4. Identify root cause: Distinguish
between symptoms and the real
issue.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Steps
5. Implement Corrective Actions:
Address the root cause (e.g.,
recalibrate equipment).
6. Monitor results: Ensure the
problem doesn’t reoccur.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Tools
Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Tools
5 Whys: Why did this happen?
Keep asking ‘why’ until you
reach the root cause.
Fishbone diagram (Ishikawa):
Organize potential causes into
categories like Equipment,
Process, People, etc.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Tools
Pareto analysis: Focus on the
20% of causes creating 80%
of the issues.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Example
Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Problem

A batch of pasteurized milk


failed microbial testing

due to high Total Plate Count


(TPC)

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
5 Whys Analysis
1. Why did the milk fail microbial
testing?
The microbial count was above
the acceptable limit after
pasteurization.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
2. Why was the microbial count
high after pasteurization?
The pasteurization temperature
was below the required 72°C for
15 seconds.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
3. Why was the pasteurization
temperature below 72°C?
The temperature sensor in
the pasteurizer was not
functioning correctly.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
4. Why was the temperature
sensor not functioning correctly?
The sensor was overdue for
calibration and maintenance.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
5. Why was the calibration not
done on time?
There was no automated
system or checklist to track
maintenance schedules.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Root cause
Failure to implement a system
for tracking and performing
timely calibration of critical
equipment.

Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst
Useful?
Repost
Ayqa Shabbir
Assistant Food Safety Officer, Data Analyst

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