Root Cause Analysis (RCA) is a series of investigative processes used by many industries to discover underlying problems. RCA goes beyond identifying the issue - it works to find the underlying problems in the process and not the defects themselves. The real value in this approach lies in identifying the root cause and eliminating it, which helps things run more efficiently. While this seems simple, it is actually quite complex. Luckily, there are tried and tested root cause analysis tools that you can use to more easily identify underlying issues and eliminate them before they spread.
In this article, we’ll tell you everything you need to know about Root Cause Analysis while providing examples of how they manifest in the real world.
Root Cause Analysis Tools
Root cause analysis (RCA) is a common and effective methodology used to identify the reasons behind a problem or failure. The right root cause analysis tools help businesses discover underlying issues to problems and provide actionable feedback that lead to a resolution.
Below are five root cause analysis tools you can start using today:
1. The 5 Whys
This technique involves asking “Why?” five times until you identify the underlying cause of a problem. This root cause analysis tool is simple, effective, and widely used in manufacturing and Six Sigma. This article has a great deep dive into this concept.
2. Fishbone Diagram (Ishikawa)
Also known as the Cause-and-Effect diagram, this root cause analysis tool helps categorize potential causes into groups such as People, Process, Equipment, and Environment—making it easier to brainstorm and investigate.
3. Pareto Chart
Based on the 80/20 rule, the Pareto Chart helps teams focus on the most significant problems by visualizing which causes have the biggest impact.
4. Scatter Diagram
A scatter diagram shows relationships between two variables, making it easier to spot trends or correlations that may point to the root cause of a problem. These days, advances in AI make analyzing this chart to identify defects incredibly effective.
5. Failure Mode and Effects Analysis (FMEA)
FMEA evaluates potential failure modes within a system and analyzes their impact, allowing teams to address high-risk issues before they occur.
Root Cause Analysis Examples
Understanding how root cause analysis (RCA) works in the real world is just as important as knowing the tools. These root cause analysis examples demonstrate how businesses across industries solve problems from the ground up.
1. Manufacturing Defect
- Problem: A factory sees an increase in defective parts.
- Tool Used: 5 Whys
- Root Cause: A machine was misaligned after recent maintenance.
2. Software Downtime
- Problem: An app frequently crashes during peak usage.
- Tool Used: Pareto Chart
- Root Cause: 80% of crashes were traced to one outdated server instance.
3. Customer Complaint Spike
- Problem: A sudden rise in negative customer reviews.
- Tool Used: Fishbone Diagram
- Root Cause: A miscommunication in shipping policies during a promotion.
4. Healthcare Equipment Failure
- Problem: An imaging device intermittently fails.
- Tool Used: Scatter Diagram
- Root Cause: Power surges during late-night usage correlated with outages.
5. Assembly Delay
- Problem: An automotive manufacturing plant keeps falling behind schedule.
- Tool Used: FMEA
- Root Cause: The delay was linked to one supplier's inconsistent delivery schedule.
These root cause analysis examples show how structured tools lead to clearer insights—and better outcomes.
Root Cause Analysis FAQ
What is the 5 Whys tool for root cause analysis?
The 5 Whys is a simple problem-solving method where you ask "Why?" multiple times to uncover the root cause of an issue. It's often the first step in a deeper analysis.
What are the 5 P's of root cause analysis?
The 5 P’s typically refer to People, Processes, Policies, Procedures, and Plant (or Place). These categories help teams examine different areas where a problem might originate.
What are the 5 steps of root cause analysis?
- Define the Problem
- Collect Data
- Identify Possible Causes
- Determine the Root Cause
- Implement and Monitor Solutions
Using the right root cause analysis tools can help your business get ahead of costly issues before they become bigger problems. When paired with real-world insights like the root cause analysis examples we’ve shared, these tools become powerful drivers of performance, reliability, and quality.