Topic guide · 25 articles
Root cause analysis and problem solving
Root cause analysis is the structured investigation that finds the underlying condition behind a manufacturing problem, so the fix removes the cause instead of the symptom and the problem stops coming back. It starts with a precise, factual problem statement and then uses the tool that fits the problem: the 5 Whys for a single chain of cause and effect, a fishbone diagram when causes sit in several areas at once, and A3 or 8D for larger, cross-functional problems. These guides explain each method, when it works and when it does not, and how to move a plant from daily firefighting to real problem solving.
Quick guide: The 6 Ms of production
Also: Model area 90-day plans
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- 1
The 6Ms of Production: A Complete Manufacturing Guide
The 6 Ms are Man, Machine, Method, Material, Measurement and Mother Nature. See what each covers and how to use them to find a problem's root cause.
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5G Methodology: Toyota's Problem Investigation Framework
The 5G method checks five things before naming a cause: Gemba (place), Gembutsu (object), Genjitsu (facts), Genri (principles), Gensoku (standards).
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5W1H Method: Defining Problems for Root Cause Analysis
5W1H asks What, Who, Where, When, Why and How to define a problem before root cause analysis. Each question, a worked example, and 5W1H vs 5 Whys.
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All 25 articles on root cause analysis and problem solving
Root cause analysis basics (3)
Defining the problem (4)
5 Whys and fishbone diagrams (6)
- What is the 5 Whys Root Cause Analysis Method?
- 5 Whys: When It Works and When It Doesn't
- Fishbone Diagram: A Root Cause Analysis Visual Tool
- Fishbone Diagrams: Effective Facilitation Techniques for Manufacturing Teams
- The 6Ms of Production: A Complete Manufacturing Guide
- The 5Ms of Lean Manufacturing: How Fishbone Diagram Categorizes Causes
A3, 8D and fault tree analysis (5)
From firefighting to daily problem solving (7)
- The 3-Step Framework to End Daily Issue Firefighting
- Why Firefighting Kills Manufacturing Productivity in 2026
- From Reactive Firefighting to Proactive Operations: 90-Day Plan
- Daily Issue Chaos Costs Manufacturers $1.7M Annually
- Breaking the Cycle of Shop Floor Chaos Forever
- Real-Time Problem Dashboards End Shift Reports Forever
- Why Digitize Abnormality Reporting (F-tags)
Where LeanSuite helps
AI Root Cause Analysis
Describe a problem, answer the AI's questions, and get the likely root causes and an action plan.
See AI Root Cause AnalysisDaily Issue Management
Gives frontline teams one place to flag, track and resolve issues in real time, so the same fires stop coming back every week.
See Daily Issue ManagementNon-Conformance (NCR)
Moves non-conformance reports into an automated workflow and links each defect report to root-cause problem solving.
See Non-Conformance (NCR)
Free templates
- 5W1H templateSix questions with prompts and evidence, turned into a problem statement before the root cause analysis.
- 5 Whys templateA problem statement, five why rows with evidence, the root cause and the countermeasure.
- 8D report templateD0 to D8 on three pages: team, is/is not, containment, occurrence and escape causes, actions and closure.
- A3 problem solving templateThe standard seven-box A3 from background to follow-up, with a filled-in worked example. PDF and Excel.
- Pareto chart templateA tally sheet, the categories sorted largest first with cumulative %, and the chart. Excel does the sorting and drawing.
- Corrective action request (CAPA) formProblem, containment, root cause, corrective and preventive action, and proof the fix worked, on two pages.
- Incident investigation report templateWhat happened, people, evidence and timeline, root cause with 5 Whys and contributing factors, actions and sign-off.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- 5G investigation sheetConfirm the facts before naming a cause: 5W1H, the five G's with 20 prompts, the gap against the principle and the standard, and the countermeasures.
- Is / is not analysis templateWhat, where, when and extent with is, is not, distinctions and changes, then each possible cause tested against every pair and ranked.
- Fault tree analysis templateA drawing area with the FTA symbols, an event table with probabilities and minimal cut sets, and the gates worked out bottom-up in Excel.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Scatter diagram templateUp to 50 pairs with a group code, r and R², the least squares line, the quadrant count and r for each group.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
Free training decks
Free printable posters
- PDCA cycle posterPlan, do, check, act as a cycle, with what to do in each step.
- 5 whys posterOhno's classic machine example, from a blown fuse to a missing strainer, with the rules for asking why.
- 8D problem solving posterThe eight disciplines plus D0, from forming the team to recognizing it, in one view.
- 7 basic quality tools posterIshikawa's seven tools, each drawn and explained in one line.
FAQ
Questions about root cause analysis and problem solving
More topics
- Lean manufacturing fundamentals
- Kaizen and continuous improvement
- Quality management
- TPM and maintenance
- 5S and visual management
- Value stream mapping and flow
- Standard work, SOPs and training
- Safety management
- Lean leadership and employee engagement
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