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Ishikawa Fishbone Diagram for Investigating Root Causes

An Ishikawa Diagram, also known as a Fishbone Diagram or Cause and Effect Diagram, is a visual tool used to systematically identify and present all the possible causes of a specific problem or effect. It was developed by Kaoru Ishikawa and is commonly used in quality management and problem-solving processes.


Structure:
The diagram looks like the skeleton of a fish:
The head represents the problem or effect.
The spine is the central line connecting to the head.
The bones (branches) represent major categories of causes.
Smaller bones branching off the main ones show more specific causes.

Common Cause Categories (6Ms for Manufacturing):

1. Man – People involved

2. Machine – Equipment and tools

3. Method – Processes and procedures

4. Material – Raw materials or consumables

5. Measurement – Inspection, calibration, and data

6. Mother Nature (Environment) – Surroundings and conditions

Example Use Case:
If a factory faces product defects, the Fishbone Diagram helps break down potential causes under categories like human error, machine failure, incorrect materials, etc., to identify root causes.

Here's an example of a Fishbone (Ishikawa) Diagram for investigating the root causes of spillage of a liquid bulk product in the pharmaceutical industry:

Effect (Problem at the Head):
Spillage of Liquid Bulk Product

Categories and Possible Causes:

1. Man (Personnel)
Inadequate training on handling procedures
Operator error during transfer
Miscommunication between shifts
Fatigue or distraction

2. Machine (Equipment)
Faulty valve or gasket
Leak in transfer hose or pipe
Inaccurate level indicators
Pump malfunction

3. Method (Process)
Incorrect SOP followed
Overfilling of container
Improper connection of transfer lines
Lack of pre-transfer checks

4. Material (Product & Packaging)
Incompatible container materials
Damaged or low-quality containers
Incorrect product labeling causing misuse

5. Measurement
Faulty volume sensors or gauges
Inaccurate flow meters
Absence of visual checks for level

6. Environment (Mother Nature)
Wet or slippery floor increasing accident risk
Poor lighting in work area
Temperature fluctuations affecting product viscosity

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#QualityAssurance
#CAPA
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