manufacturing root cause analysis

THE BUSINESS PROBLEM
Every assembly line has a long list of problems that need to be addressed. The quality teams will typically build a pareto chart of defects and tackle the most frequent issues at the left of the chart.

They rarely have the time or resources to address the long tail of issues — even though, cumulatively, that long tail is quite significant.

As a result, the pursuit of zero defects hits a limit. Quality issues keep recurring, creating ongoing risk to the business.

Here’s how Drishti helps an auto-tier one increase their capacity to solve many more issues.

WHAT’S THE CURRENT METHODOLOGY?
The core obstacle is that root cause analysis takes days.

Without Drishti, when a defect occurs, quality teams must perform manual root cause analysis. Quality engineers will spend a great deal of time on the line measuring, observing, testing, interviewing operators, conducting experiments, tearing down units, and performing other activities, all to generate hypotheses as to why the defect occurred.

This root cause analysis takes a considerable amount of time. In fact, this is a major opportunity cost: The time spent performing root cause analysis on any one defect crowds out the opportunities to address other defects. Quality teams must therefore prioritize, which results in the long tail of defects going unaddressed.

HOW DRISHTI HELPS
Drishti Trace provides complete video traceability for station activities. When a defect is discovered, a quality engineer can review actual footage of the assembly issue as easily — and as quickly — as finding a video on YouTube. Features include:

  • Browse and filter video clips by date, time, product, line, station, etc.
  • Search by unit serial number to see a “birth certificate”
  • Replay videos in real-time, in slow motion, or up to 4x speed
  • Perform time studies and video analysis using video software
  • Share videos to collaborate with off-site colleagues
  • Integrate video clips into reporting and training processes

With this ability to “see backwards in time”, root cause analysis is significantly accelerated. In many cases, the root cause is observable in the video; even if it’s not, the quality engineer has significantly narrowed the hypothetical causes.

In either event, the investigation is far quicker, and results in much greater certainty than traditional methods.

KPIs AND SUCCESS METRICS
When defects require fewer resources to address, quality teams gain capacity to address many more. They are able to go much further down the long tail of defects, and reduce the overall defect rate.

Read more about Drishti Trace.