PROBLEM SOLVING &

ROOT CAUSE ANALYSIS

If there’s no time to do it right the first

time,
you will have to find the time to do it
over…
and over.…
 OBJECTIVE
Continuously Improve Quality by
ELIMINATING the causes of problems and
PREVENT their reoccurrence

Peningkatan Kualitas berkelanjutan dengan

mengeliminasi penyebab permasalahan dan
mencegah terjadi kembali
 5 WHY PROBLEM
SOLVING
DEFINE THE PROBLEM
Good problem statement use 5W + 1H to describe the
1 DEFINE THE PROBLEM Problem
Who When
What Where
TAKE CONTAINMENT
2 Why How
ACTION

Example:
3
DETERMINE ROOT Endline QC found 3 Pcs of garments defected by oil stain
CAUSE
during perform Endline Inspection in QC Table
DEVELOP/DETERMINE
4 CORRECTIVE/
PREVENTIVE ACTION
Describe the problem in measurable terms. Avoid to use
“because” or “due to” when defining a problem
VERIFY THE
5
EFFECTIVENESS
 5 WHY PROBLEM 2.1 DEFINITION

SOLVING Actions taken to isolate the problem from any

internal/external customer.

1 DEFINE THE PROBLEM 2.2 OBJECTIVE

The objective of this step is to isolate the effects of the
problem by implementing containment actions.
TAKE CONTAINMENT
2
ACTION Once a problem has been described, immediate actions
are to be taken to isolate the problem from the
customer. In many cases the customer must be notified
3
DETERMINE ROOT of the problem.
CAUSE

DEVELOP/DETERMINE 2.3 EXAMPLE OF CONTAINMENT ACTION

4 CORRECTIVE/ • Mark and segregate defective garment
PREVENTIVE ACTION
• Rework defective garment

5
VERIFY THE • Wash stain
EFFECTIVENESS
 3.1 OBJECTIVE
5 WHY PROBLEM • Identify potential causes which could explain why the
problem occurred.
SOLVING
• Test each potential cause against the problem description
and data.

1 DEFINE THE PROBLEM • Identify alternative corrective actions to eliminate root

cause.

TAKE CONTAINMENT 3.2 DETERMINE ROOT CAUSE USING 5 WHY

2
ACTION

DETERMINE ROOT
3
CAUSE

DEVELOP/DETERMINE
4 CORRECTIVE/
PREVENTIVE ACTION

VERIFY THE
5
EFFECTIVENESS
 EXAMPLE:
5 WHY PROBLEM Endline QC found 3 Pcs of garments defected by oil
SOLVING stain during perform Endline Inspection in QC Table

Leaking on obrass machine Why?

1 DEFINE THE PROBLEM

Dust clogged some parts Why?

TAKE CONTAINMENT Therefore
2
ACTION
Machine was not properly cleaning Why?
Therefore
DETERMINE ROOT
3
CAUSE
Operator don’t know how to clean Why?
Therefore
DEVELOP/DETERMINE obrass machine properly
4 CORRECTIVE/
PREVENTIVE ACTION
No training was provided to operator
Therefore
(the root cause)
VERIFY THE
5
EFFECTIVENESS
 5 WHY PROBLEM
SOLVING

1 DEFINE THE PROBLEM

TAKE CONTAINMENT
2
ACTION

DETERMINE ROOT
3
CAUSE

DEVELOP/DETERMINE
4 CORRECTIVE/
PREVENTIVE ACTION

VERIFY THE
5
EFFECTIVENESS
 5 WHY PROBLEM
SOLVING

1 DEFINE THE PROBLEM

TAKE CONTAINMENT
2
ACTION

DETERMINE ROOT
3
CAUSE

DEVELOP/DETERMINE
4 CORRECTIVE/
PREVENTIVE ACTION

VERIFY THE
5
EFFECTIVENESS