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Analyze
Analyze
Analyze
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Analyze Phase
Goal: To identify potential root causes and to confirm real causes
using data.
Output Deliverables:
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BRAINSTORMING
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What is Brainstorming?
▪ A technique used to generate ideas from a group of individuals in any
stage of any problem solving activity.
▪ The more alternative choices we have, the better our decision is.
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Brainstorming Methods
✓Structured
✓Unstructured
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Brainstorming Rules
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5 Whys (Why-Why) Analysis
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Why – Why Analysis in Action #1
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Why – Why Analysis in Action #2
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Why – Why Analysis in Action #3
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Why – Why Analysis in Action #4
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How to Get Started with Why - Why
3. Ask Why
4. Validate
5. Take Action
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FISHBONE
DIAGRAM
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What is a Fishbone (Cause & Effect) Diagram?
▪ Use your team's process knowledge about the entire process to create
an effective cause-and-effect diagram.
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How to Construct a Fishbone Diagram?
1) Generate potential causes of a problem through brainstorming.
3) Decide upon the major cause categories of the event, problem, or key
characteristics.
4) Write the major cause categories on the left-hand side of paper and draw
lines to them off the main horizontal line.
5) Conduct a Why – Why Analysis by asking why questions that can lead to
the potential root causes.
6) Look for causes that appear repeatedly. These may represent root causes.
Look for what you can measure in each cause so you can quantify the
effects of any changes you make. Most importantly, identify and circle
the causes that you can take action to.
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Fishbone Diagram Sample #1
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Fishbone Diagram Sample #2
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Fishbone Diagram Sample #3
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Root Cause Analysis Tips
2. Did you find a root cause that helps you control or avoid the
situation?
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GRAPHICAL
ANALYSIS
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Graphical Analysis Tools
▪ These are set of tools used to validate the hypotheses or potential root
causes identified from the root cause analysis.
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DATA
DISTRIBUTION
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Graphical tools for the distribution of data
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HISTOGRAM
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What is a Histogram?
A histogram is a plot that lets you discover, and show, the
underlying frequency distribution (shape) of a set
of continuous data. This allows the inspection of the data for its
underlying distribution (e.g., normal distribution), outliers,
skewness, etc.
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Anatomy of a Histogram
Histogram of None, GrowFast, SuperPlant
Normal Central Tendency
Vari abl e
0.09 N on e
Grow Fast
0.08 SuperPl ant
0.05
0.04
0.03
0.02
0. 01
0.00
8 12 16 20 24 28 32 36
Data
Dispersion
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Typical Types of Histogram
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Typical Types of Histogram
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Histogram Using Minitab #1
0.04
0.03
0.02
0. 01
0.00
8 12 16 20 24 28 32 36
Data
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BOXPLOT
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What is a Boxplot?
A box and whisker plot is defined as a graphical method of
displaying variation in a set of data. In most cases, a histogram
analysis provides a sufficient display, but a box and whisker plot
can provide additional detail while allowing multiple sets of data
to be displayed in the same graph.
Target
A B
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Boxplot
Anatomy of aofBox
None,Plot
GrowFast, SuperPlant
* Outlier
4th Quartile
3rd Quartile
Inter Quartile Range 2nd Quartile | Median
(IQR)
1st Quartile
IQR = Q3 – Q1
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Boxplot Using Minitab #1
35
30
Multiple Y's 20
15
10
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PARETO CHART
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What is a Pareto Chart?
▪ A bar chart where the bars are arranged in descending order of magnitude.
The bars may represent defect categories, locations, departments, and so on.
▪ Typically, 80% of the effects come from 20% of the possible causes, so efforts
are best spent on these “vital few” causes, temporarily ignoring the “trivial
many” causes.
▪ Most commonly used for prioritization of resources and also for validation of
root causes.
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Anatomy of a Pareto Chart
Cumulative
%
Categories
Frequency
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How to Create a Pareto Chart?
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How to Create a Pareto Chart?
6. Determine the appropriate scale for the measurements you have collected. The
maximum value will be the largest subtotal from step 5. (If you will do optional steps 8
and 9 below, the maximum value will be the sum of all subtotals from step 5.) Mark the
scale on the left side of the chart.
7. Construct and label bars for each category. Place the tallest at the far left, then the next
tallest to its right, and so on. If there are many categories with small measurements, they
can be grouped as “other.”
8. Calculate the percentage for each category: the subtotal for that category divided by the
total for all categories. Draw a right vertical axis and label it with percentages. Be sure
the two scales match. For example, the left measurement that corresponds to one-half
should be exactly opposite 50% on the right scale.
9. Calculate and draw cumulative sums: add the subtotals for the first and second
categories, and place a dot above the second bar indicating that sum. To that sum add
the subtotal for the third category, and place a dot above the third bar for that new sum.
Continue the process for all the bars. Connect the dots, starting at the top of the first bar.
The last dot should reach 100% on the right scale.
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Pareto Chart Sample Using Minitab #1
A quality engineer for an automotive supply company wants to decrease the
number of car door panels that are rejected because of paint flaws. The
engineer wants to determine whether a relationship exists between the type
of paint flaws and the shift during which the door panels are made.
Source Sheet: Flaws
Defects: Flaws
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Pareto Chart Sample Using Minitab #2
A clothing manufacturer tracked the number and type of defects in a line of clothing.
Stat > Quality Tools > Pareto Chart Stat > Quality Tools > Pareto Chart
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Things to consider when you use a Pareto chart, p1
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Things to consider when you use a Pareto chart, p2
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Things to consider when you use a Pareto chart, p3
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TIME SERIES
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Graphical tools for variables over time
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TIME SERIES
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What is a Time Series?
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Anatomy of a Time Series Chart
Data
Points
Time
Elements
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Why use time series chart?
To check for patterns:
▪ Trend
▪ Shift
▪ Cycle
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Time Series Sample #1
The manager of a shipping yard wants to study the amount of cargo that is
transported. The manager collects the weight of all the cargo that passes through
the shipping yard each month.
Series: Weight
Time/Scale: Stamp >
Month
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Time Series Sample #2
The administrator of a hospital wants to examine the number of cardiac patients
admitted over the past 24 months to analyze trends in the data.
440
380
360
Series: No. of Patients
340
Month 300
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
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RELATIONSHIP
BETWEEN VARIABLES
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Graphical tools for relationships between variables
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SCATTER PLOT
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What is a Scatter Plot?
▪ It is a problem solving tool and is also known as the correlation diagram.
▪ It cannot prove that one variable causes another, but it does show
how a pair of variables is related and the strength of that relationship.
Statistical tests quantify the degree of correlation between the variables.
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Anatomy of a Scatter Plot
Best
Fit
Line
Paired
Data
Points
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How to Interpret a Scatter Plot
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Scatter Plot Sample Using Minitab #1
A research team at a fitness assessment company is looking for a method to predict a
person's body fat percentage. This health measure is difficult and expensive to measure
directly. In its model, the team wants to include a predictor variable that is easier to measure,
and is considering the use of Body Mass Index (BMI).
45
With Regression 30
25
Y Variables: %Fat 20
X Variables: BMI 15
15 20 25 30 35
BMI
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Scatter Plot Sample Using Minitab #2
A food scientist wants to determine the optimal time for heating a frozen dinner. The
scientist prepares 14 samples at various times and temperatures, and then has
professional food tasters rate each sample for overall quality.
Y Variables: Quality
X Variables: Time
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Scatter Plot Sample Using Minitab #3
A quality engineer for a camera manufacturer wants to shorten the flash recovery
time. Flash recovery time is the least amount of time that is required between flashes.
The engineer wants to determine whether a relationship exists between the voltage
that remains in the camera battery immediately after a flash and the flash recovery
time.
Source Sheet: Flash
Y Variables: Flash
X Variables: Volts
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VALIDATION
TABLE
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When to Best Use Each Graphical Tool
Y Continuous Categorical
Histogram
Box Plot
Continuous Scatter Plot
Pareto (prioritization)
Time Series (over time)
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What is a Validation Table?
A validation table is a simple table that summarizes the efforts done in
generating and validating the potential root causes. It will give the team an
idea of which has been valid root causes among all the generated potential
root causes.
Validation Method
(Observation, Records
Potential Root Causes Conclusion
Checking,
(Valid or Not Valid)
Data/Graphical
Analysis, etc.)
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