16Analyzing Product Failures and Root Causes
The root cause is the most basic causal factor or factors that, if corrected or removed, will prevent the recurrence of a problem. It is generally understood that problem identification and correction requires getting to the root cause. This chapter discusses root-cause analysis concepts, presents a methodology for root-cause analysis, and provides guidance for decision making.
Generally, product failures or faults do not “just happen.” Products fail due to “failures” in design, manufacture, assembly, screening, storage, transportation, operation, and even in repair and maintenance.
The root cause is the most basic causal factor or factors that, if corrected or removed, will prevent the recurrence of the failure. Identifying root causes is the key to preventing similar occurrences in the future.
Root cause should not be confused with symptoms and apparent causes of failure. A symptom is a sign or indication that a failure exists. For example, a symptom of failure could be a knocking noise made by a washing machine. The apparent cause may be a rocking movement of the machine itself. However, the root cause is the most basic causal factor. In the above example, the root cause could arise because a bearing in the motor is worn, due to a lack of lubricant.
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