Root cause analysis
Root cause analysis for maintenance: 5 Whys, fishbone and follow-up
Fixing the symptom gets the machine running. Fixing the root cause stops the same job card coming back next week.
Plain-English definition
What is root cause analysis?
Root cause analysis (RCA) is a structured way of finding the underlying reason a failure happened, so the fix prevents it from happening again rather than only repairing the damage.
When to run a root cause analysis
RCA takes time, so use it where the payoff is clear.
- The same failure has happened two or three times on one asset
- A failure caused a safety incident or near miss
- A single breakdown caused major downtime or cost
- A new failure mode appears across similar machines
The 5 Whys, with an example
Ask 'why?' until the answer is something the team can change. Five is a guide, not a rule.
| Why? | Answer |
|---|---|
| Why did the conveyor stop? | The drive motor tripped on overload |
| Why did it overload? | A tail pulley bearing seized |
| Why did the bearing seize? | It ran without grease |
| Why was it not greased? | It is not on the weekly greasing route |
| Why is it not on the route? | It was added during a modification and the routine was never updated |
Fishbone diagrams for complex failures
When there could be several causes, a fishbone (Ishikawa) diagram groups possibilities under headings such as machine, method, materials, people, measurement and environment. The team then tests each one against the evidence on the job cards.
Close the loop
An RCA is only finished when a change is made and checked. In the example above, the fix is a new step on the greasing checklist and a follow-up review after a month. Without that, the analysis is a report rather than an improvement.
How UPWRKS does it
History makes repeat failures obvious.
Because every UPWRKS job card is tied to an asset, repeat breakdowns show up in the asset's history and reports. Findings, photos and follow-up jobs keep the RCA trail on the record.
Asset history shows the same fault returning.
Notes and photos capture what was actually wrong.
Follow-up jobs and new checklist steps close the loop.
RCA depends on evidence. Job cards with findings and photos give the team facts instead of memories.
Common questions
Root cause analysis FAQs
What is root cause analysis in maintenance?
It is a structured method to find why a failure happened, so the corrective action prevents it recurring.
What is the 5 Whys technique?
It is a simple RCA method of repeatedly asking 'why?' about a failure until you reach a cause the team can change.
How do I find repeat failures?
Look at the breakdown history per asset. A digital job card system makes repeats visible without searching paper files.
Who should take part in an RCA?
The technician who did the repair, an operator who runs the machine and a supervisor. People closest to the work usually know the real cause.