Search results

Some manufacturing and service organizations have made efforts to work on continuous improvement in the form of Kaizen, lean thinking, Six Sigma, etc. The elimination of problems and waste (MUDA for the Japanese) plays a fundamental role in the reduction of operational costs and quality rejections of finished products both internally in the organization and in the supply chain. Some of these efforts use quality control tools to remedy it. Kaoru Ishikawa proposes seven basic quality tools. In this group of quality tools is the cause-and-effect diagram (CED), also known as “The Fishbone” and “Ishikawa diagram”. Exploring this questioning can shed light on the first indications to ratify the arguments of Ishikawa and Deming, that the main problems of companies are found in their processes and perhaps, in a deep way, in some of these cornerstone root causes that have to do with the way organizations are managed. The purpose of this study is to investigate cornerstone root causes through the application of CEDs in 40 Mexican companies that began an effort to improve some of their organizational processes.

An exploratory qualitative study was conducted. As a research strategy, the case study method was applied. Using theoretical sampling, the Ishikawa diagrams of 40 companies were analyzed, and 24 semi-structured interviews in depth were conducted.

The results of this research confirm the main research question: Are there cornerstone root causes that give way to one or several problems or effects of problems in organizations regardless of their sector? In other words, there were at least seven typical patterns that show the first signs of cornerstones root causes in organizations.

The method itself is a limitation; 40 case studies are not enough to generalize the results. In addition, the research was conducted only in a single Latin American country; in some cities of Mexico. However, 60 per cent of these companies are multinationals.

This paper is fundamental to delve into the cornerstones causes that give rise to the problems of organizations of the twenty-first century. The authors understand that these are the first indications, and that they cannot be considered a conclusion of these causes. However, this first theoretical sampling presents a first light on the subject.

The study contributes to the limited existing literature on total quality management and Kaizen in quality control tools and subsequently disseminates this information to provide impetus, guidance and support toward improving the problems of the organizations of twenty-first century.

In continuous improvement (CI) projects, cause-and-effect diagrams are used to qualitatively express the relationship between a given problem and its root causes. However, when data collection activities are limited, and advanced statistical analyses are not possible, practitioners need to understand causal relationships. The paper aims to discuss these issues.

In this research, the authors present a framework that combines cause-and-effect diagrams with Bayesian belief networks (BBNs) to estimate causal relationships in instances where formal data collection/analysis activities are too costly or impractical. Specifically, the authors use cause-and-effect diagrams to create causal networks, and leverage elicitation methods to estimate the likelihood of risk scenarios by means of computer-based simulation.

This framework enables CI practitioners to leverage qualitative data and expertise to conduct in-depth statistical analysis in the event that data collection activities cannot be fully executed. Furthermore, this allows CI practitioners to identify critical root causes of a given problem under investigation before generating solutions.

This is the first framework that translates qualitative insights from a cause-and-effect diagram into a closed-form relationship between inputs and outputs by means of BBN models, simulation and regression.

In implementing Six Sigma and/or Lean Six Sigma, a practitioner often faces a dilemma of how to select the subset of root causes from a superset of all possible potential causes, popularly known as root cause analysis (RCA). Generally one resorts to the cause and effect diagram for this purpose. However, the practice adopted for identification of root causes is in many situations quite arbitrary and lacks a systematic, structured approach based on the rigorous data driven statistical analysis. This paper aims at developing a methodology for validation of potential causes to root causes to aid practitioners.

Discussion has been made on various methods for identification and validation of potential causes to root causes with the help of a few real life examples for effective Lean Six Sigma implementation.

The cause and effect diagram is the frequently adopted method for identifying potential causes out of a host of methods available for such identification. The method of validation depends on the practitioners’ knowledge on the relationship between cause and effect and controllability of the causes.

The roadmap thus evolved for the validation of root causes will be of great value to the practitioners as it is expected to help them understand the ground reality in an unambiguous manner resulting in a superior strategy for cause validation and corrective actions.

Poor quality of design documents and Design Deficiencies (DDs) are critical factors that can potentially cause time and cost overrun and lead to project failure. Despite the importance of this issue, few studies have been conducted to explore the underlying relations among the causes and effects of DDs, and it is not clear how they exert influence on each other. However, it is imperative to have a clear understanding of their interrelationships so as to devise intervention strategies. The purpose of this study is, therefore, to explore these causes and effects.

To this aim, a qualitative system dynamics model was provided to visualize how various factors interact with one another. The model was developed and validated by drawing on the expertise of industry-related experts. The key causes and effects of the DDs were identified through the investigation of the model.

It was concluded that design management of project and the composition of design teams are critical. The obtained results also showed that more attention should be paid to the enhancement of knowledge circulation and communication within design firms and increasing the awareness of managers and owners from the technical consequences of their managerial decisions.

It is worth mentioning that the design process could be deeply affected by the quality, frequency and strength of relationships among the project’s parties. Early involvement of contractors, for example, can significantly contribute to enhancing design quality. This study investigates factors’ interactions in projects delivered using the traditional design-bid-build method. As relationships between the project’s parties could be different in various project delivery methods, further research is indeed needed to assess factors’ interactions in projects delivered using other methods.

It is believed that the proposed model by providing a better insight into the connections of causes and effects could aid project managers of different parties with planning the strategies to reduce DDs and mitigate their effects.

The purpose of this paper is to develop a comprehensive framework for improving intensive care unit performance.

The study introduces a quality management framework by combining cause and effect diagram and logical framework. An intensive care unit was identified for the study on the basis of its performance. The reasons for not achieving the desired performance were identified using a cause and effect diagram with the stakeholder involvement. A logical framework was developed using information from the cause and effect diagram and a detailed project plan was developed. The improvement projects were implemented and evaluated.

Stakeholders identified various intensive care unit issues. Managerial performance, organizational processes and insufficient staff were considered major issues. A logical framework was developed to plan an improvement project to resolve issues raised by clinicians and patients. Improved infrastructure, state‐of‐the‐art equipment, well maintained facilities, IT‐based communication, motivated doctors, nurses and support staff, improved patient care and improved drug availability were considered the main project outputs for improving performance. The proposed framework is currently being used as a continuous quality improvement tool, providing a planning, implementing, monitoring and evaluating framework for the quality improvement measures on a sustainable basis.

The combined cause and effect diagram and logical framework analysis is a novel and effective approach to improving intensive care performance. Similar approaches could be adopted in any intensive care unit.

The paper focuses on a uniform model that can be applied to most intensive care units.

The purpose of this paper is to improve the yield of a particular model of a car windshield, as the organization faces losses due to poor performance and rejection.

The Six Sigma DMAIC (define, measure, analyze, improve and control) methodology is used to reduce variation and defects in the process. It is a methodology based on data-driven and fact-based analysis to find out the root cause of the problem with the help of statistical analysis. A worst performing model is selected as a case study through the scoping tree. The preprocess, printing, bending and layup process defects are reduced by analyzing the potential causes and hypothesis testing.

This paper describes Six Sigma methodology in a glass manufacturing industry in India for automotive applications. The overall yield of a car windshield achieved 93.57 percent against the historical yield of 88.4 percent, resulting in saving 50 lacs per annum. Due to no rework or repairing in the glass, low first-time yield causes major losses. Process improvement through focused cross-functional team reduces variation in the process. Six Sigma improves profitability and reduces defects in the automotive glass manufacturing process.

This case study is applied in automotive glass manufacturing industries. For service and healthcare industries, a similar type of study can be performed. Further research on the common type of processor industry would be valuable.

The case study can be used as a problem-solving methodology in manufacturing and service industries. The tools and techniques can be used in other manufacturing processes also. This paper is useful for industries, researchers and academics for understanding Six Sigma methodology and its practical implementation.

This case study is an attempt to solve automobile glass manufacturing problems through DMAIC approach. The paper is a real case study showing benefits of Six Sigma implementation in the manufacturing industry and saving an annual cost of 50 lacs due to rejections in the process.

A control chart is a widely used Six Sigma DMAIC process measure and control phase tool. The purpose of this paper is to contribute to the body of knowledge on applying statistical process control (SPC) methods in a pulp mill production organization and the special issues that need to be considered in this context.

The method for obtaining the results was action research, where the researcher actively participated in implementing changes in organization. Procedures to detect and further handle the deviations in a pulp mill organization were created and implemented. A cause and effect diagram used in finding causes and storing the accumulated knowledge was modified to make it applicable to this environment.

Factors for successful SPC implementation were found to be in line with earlier findings in other industries. SPC can act as a means of organizational learning in the pulp and paper industry. Specific problems in the pulp and paper industry concerning the use of SPC were the autocorrelation of data, excessive measurement variation, and limited process knowledge. The effectiveness of SPC in a pulp mill was shown both in the decreasing amount of deviations and in the positive opinions of the employees.

Findings are generated from a single case, so general applicability is limited.

This case study can be used as a benchmark by other practitioners in the industry.

This article provides new knowledge in the context of implementing SPC in a pulp and paper manufacturing organization.

This paper attempts to develop a hybrid cause and effect diagram (CED) and interpretative structural model (ISM) for root cause analysis in quality management. The proposed model overcomes the weakness of the CED in reliably articulating hierarchical cause–effect Relationships.

A focus group discussion (FGD) among quality experts in the case company to establish relationships between the determined causes.

The hybridization of the CED and ISM allowed the causes to be ordered more clearly to determine potential root causes as well as presenting these causes more comprehensively.

The paper has been one of the very few attempts to improve the CED approach. As such, this paper employs the ability of the ISM to order concepts in a hierarchical structure, which is useful in determining root causes.

Learning outcomes are as follows: students will discover the importance of process orientation in management; students will determine the root cause of the problem by applying root cause analysis technique; students will identify the failure modes, analyze their effect, score them on a scale and prioritize the corrective action to prevent the failures; students will analyze the processes and propose error-proof system/s; and students will analyze organizational culture and ethical issues.

Purpose: This case study is intended as a class-exercise, for students to discover the importance of process-orientation in management, analyze the ethical dilemma in health care and to apply quality management techniques, such as five-why, root cause analysis, failure mode and effect analysis (FMEA) and error-proofing, in the management of the health-care and service industry. Design/methodology/approach: A voluntary reporting of a case of “radiation overdose” in a hospital’s radio therapy treatment unit, which led to an ethical dilemma. Consequently, a study was conducted to establish the causes of the incident and to develop a fail-proof system, to avoid recurrence. Findings: After careful analysis of the process-flow and the root causes, 25 potential failure modes were detected and the team had assigned a risk priority number (RPN) for each potential incident, selected the top ten RPNs and developed an error-proofing system to prevent recurrence. Subsequently, the improvement process was carried out for all the 25 potential incidents and a new control mechanism was implemented. The question of ethical dilemma remained unresolved. Research limitations/implications: Ishikawa diagram, FMEA and Poka-Yoke techniques require a multi-disciplinary team with process knowledge in identifying the possible root causes for errors, potential risks and also the possible error-proofing method/s. Besides, these techniques need frank discussions and agreement among team members on the efforts for the development of action plan, implementation and control of the new processes. Practical implications: Students can take the case data to identify root cause analysis and the RPN (RPN = possibility of detection × probability of occurrence × severity), to redesign the protocols, through systematic identification of the deficiencies of the existing protocols. Further, they can recommend quality improvement projects. Faculty can navigate the case session orientation, emphasizing quality management or ethical practices, depending on the course for which the case is selected.

MBA or PG Diploma in Management – health-care management, hospital administration, operations management, services operations, total quality management (TQM) and ethics.

Teaching Notes are available for educators only.

CSS 9: Operations and Logistics.