Root Cause Analysis in Aerospace Manufacturing – The Five Whys and Six Sigma DMAIC
In the complex world of modern aerospace manufacturing, root cause analysis (RCA) is more crucial than ever. Whether a part fails entirely or simply fails to perform as expected, we have to thoroughly analyze the potential causes from every angle. Only then can we drill down to the true underlying issue, and ultimately improve upon the part design or manufacturing process so that the issue is resolved.
That’s where the “Five Whys” method comes into play, along with the Six Sigma model of “Define, Measure, Analyze, Improve, Control” (DMAIC).
The Five Whys Explained as Related to Aerospace Manufacturing
The Five Whys is a versatile problem-solving method commonly employed by aerospace manufacturers for root cause analysis. It helps us identify the actual underlying issues that lead to subpar quality, functionality, performance, or longevity. Moreover, it gives us a plan of action to correct the issue.
As the name suggests, the method involves asking “why” iteratively – typically framed as a five-step process – drilling down into the true cause-and-effect nature of the issue at hand.
Essentially, we repeatedly question why the issue arose until we arrive at an actionable response. We then take the necessary steps to improve upon the design, materials, or production process and develop a better end product that meets all functional requirements.
Six Sigma DMAIC Explained: Design, Measure, Analyze, Improve, Control
Six Sigma DMAIC is a data-driven methodology which we use in conjunction with the Five Whys approach to optimize the production process and eliminate quality issues, part defects, or variability. The DMAIC process can play a critical role in achieving high-quality production parts with the highest level of repeatability, thus meeting the stringent safety and precision standards of the modern aerospace industry.
- Define – We start by identifying the problem or opportunity for improvement in manufacturing. This often involves stepping back and looking at the overall production process from a holistic perspective. We can then define the specific issues, resolutions, and plans of action.
- Measure – We quantify the current process and results to create a baseline. We gather all relevant data for analysis to likewise quantify the progress and improvements that we make.
- Analyze – We carefully analyze the data, using it to identify specific root causes for the issue at hand or for inefficiencies in the production process. Combined with the prior two steps, this lays out an actionable plan for improvement.
- Improve – Finally, we implement solutions to address the root causes previously identified. These are carefully laid out plans of action involving much further data measurement and analysis to confirm results.
- Control – After we implement design and/or process improvements, we ensure the improvements are sustained in future production runs.
Why Root Cause Analysis Is Crucial in Modern Aerospace Manufacturing
In modern aerospace manufacturing, precision and safety are paramount, and quality standards are extremely strict. Both the Five Whys and Six Sigma DMCA are effective tools which help us minimize manufacturing errors and defects, while simultaneously maximizing end product safety, performance, and longevity.
Before manufacturing is fully underway, the Five Whys help us avoid defects by uncovering issues in design, material quality, or manufacturing processes. That simultaneously improves safety, identifying the root causes of potentially hazardous flaws and helping to prevent critical failures.
Likewise, the process ensures compliance with regulatory protocols by addressing gaps that could lead to non-conformance with industry standards. Finally, root cause analysis can actually streamline the overall manufacturing process through revealing inefficiencies and bottlenecks within the production line.
Superior American Manufacturing for the Aerospace Sector and Beyond
Snowline is proud to serve as one the nation’s leading aerospace engineering and manufacturing providers. In addition to custom fabrication and welding, we offer comprehensive contract manufacturing services designed to streamline your project and simplify your supply chain. Based out of Sacramento, California, our company has served leading aviation and spaceflight customers worldwide since 1966.