What is a cause and effect

diagram?
Any defect in a component, a
product or service could be
due to one or more causes. To
find out the relationship
between the causes and
effect, a diagram is drawn
systematically by mapping out
all the probable causes
influencing the effect. This is
called a cause and effect
diagram.
 WHY DOES
QUALITY
DISPERSION
OCCUR ?
It is mainly because
of inherent
variation in input
such as….
Raw material quality, variation in
composition, dimension etc
Tools, machine or equipments - not
functioning uniformly.
 The work system or process -
variation from prescribed level.
Varying moods and concentration of
the operator.
The measurement etc
 Chance cause

Upper
control
Limit

Central
Line

Lower
control
Limit

As long as these variations are within

the allowable level, we attribute to
'Chance Cause'.
 Assignable cause
Upper
control
Limit

Central
Line

Lower
control
Limit

When they are beyond the limit

allowable, we attribute to 'assignable
cause'.
When assignable cause is noticed in a
process, we take efforts to eliminate
them.
Problems can be divided into three groups
as due to
Madam, the problem is
pretty clear to us. This is
the solution suggested by
the engineer. Should we
proceed further ?

a) Visible causes which can be solved by

taking appropriate action immediately.
 Actual Observation
No PARAMETER
Spec. 1 2 3 4 5

1. Axial clearance 0.1.0.45 6.3 0.18 0.22 0.17 0.21

2. Cleanliness of Crank S Clean OK OK Not OK OK OK
3. Surface finish 0.4 300 320 325 315 300
:
:
:
:
24. Paint Finish Glossy OK OK OK OK OK

b) Some causes which can be understood only by

collection of data. Such data collection helps us
to get a clear picture. Then it can be solved.
 What the hell could
the problem be ?!!

c) But there are certain persistent problems.

What we see is only symptoms and the real
cause is elusive and difficult to find out.
 WAIT I WILL HELP!!!!
HELP YOU

Many times our efforts are only 'fire fighting'

and the assignable causes do not get
altogether eliminated. They occur again and
again
Such dispersion in quality are called
persistent defects and call for orderly
study
IN THIS CASE COMPUTER MALFUNCTION.

For eliminating such defects we should

know the root causes
 PLEASE TELL ME I WON’T
WHAT WENT TELL
WRONG. YOU.

They are normally known to the person

involved in the process
 …and then you
know what
happened.

They are expressed as verbal

information
Such verbal information need to be gathered
and organised properly so that we can get a
better picture and also collect data on them
 Best way will be to get the views of
everyone and arrange them in a proper
manner. Collect data. Based on the data
proceed further.
 What is the benefit of this system?
WHY
WHEN
WHAT
WHO
WHERE
HOW
Here we proceed in an organised way asking
relevant questions using five W ’s and one H.
This was introduced by Dr. K. Ishikawa.
He used it in Kawasaki Iron Works in
1943.
 Work
Materials methods

Quality

Equipment Measurement

Earlier it was used for research work.

This is also known as Ishikawa Diagram
Since final diagram looks like a fish bone it is
also called as fish bone diagram
 Looking into its
usefulness
Japan Standards
Institute
recognised it as
a statistical tool.
CAUSE AND EFFECT DIAGRAM
ALSO KNOWN AS:
- FISH BONE DIAGRAM
-ISHIKAWA DIAGRAM
-HERRING BONE DIAGRAM
-FISHIKAWA DIAGRAM

1 27
1 28
DISPERSION ANALYSIS TYPE
Cause & effect Diagram
1 30
However there are the three types of
Cause and Effect diagram which are very
popular viz

a) Dispersion Analysis Type.

b) Production Process Classification

Type and

c) Cause Enumeration Type

We can similarly use five Ms and four Ps
appropriately.

MAN
PEOPLE
MATERIAL
PROVISION
METHOD
PROCEDURE
MACHINE
PLACE
MEASUREMENT
 DISPERSION ANALYSIS TYPE
At the initial stage circle may use Man,
Machine, Material, Method, Environment
etc, but later on they may use other
appropriate headers

1 33
 DISPERSION ANALYSIS TYPE
In this type of cause and effect diagram
first header to be decided then causes, sub
causes, sub-sub causes and so on

1 34
FOUR MAIN CAUSES
WERE IDENTIFIED
BOWLING
BATTING
FIELDING
OTHERS
 Kumble not a big
Bowling spinner of the ball
Not enough seamers in India

Wicket was
Indian pitch
do not help Very few flat & grassy
seamers Pace
academies Spinners unable
Inadequate to exploit
pace attack conditions
Bowling in net Most
without proper spinners in a Had to sacrifice
warm up. bad patch spinner for extra
Fitness problem to few seamers batsmen
Few bowlers lacked commitment Not enough spinners in team
Main bowlers sick

Bowling Not enough

lacked punch Experience
Highly
Flat track motivated Regional politics
Frustrated spinners opposition
Bad team
Not motivated enough selection
DEFEAT IN
TEST
MATCH
 Not enough practice in Batting
fast wickets Few batsmen having
Lack of foresight by fitness problems
No time to selectors
practice
Lack of Tech. Bad team
To face Pacers Selection
Different
wickets
back home Politics at
regional level
Batsmen lack good
backfoot tech. Opening batters could not see
the new ball through
Lack of concentration
Unsure of his No specialist
place in team openers
Irresponsible
Irresponsible Main batsmen
shots
shots exposed to
Infighing in new ball
the team
No proper instructions
from Captain DEFEAT IN
TEST MATCH
 Fielding No fielders where batsmen
Lack of practice plays his favorite shots
Lack of
strategy Batsmen not
studied
Misfieding properly

Bad field
Placement No specialist Bad field
fielders placement
No Sp. Fielders at Sp. positions
Wrong fielders at wrong postions ego hassles

No game plan
Dropped Bowlers not consulted
catches
No specialist Lack of catching
slip fielders practice DEFEAT IN
TEST MATCH
 Captain cannot
No basic strategy Others motivate
Improper
Players do batting order
not No time to Not
contribute prepare respected
by Lot of new Lack of
No professional teammates batsmen foresight
ego hassles
strategist
consulted
Strategy Bad
Lack of captaincy
No batsmen proff. Ego
takes lead help problems
Lack of
Lack strategy Immaturity
Inability of
Videos Improper field
No game plan to play Batsmen not placement
fast bowling studied DEFEAT IN
TEST MATCH
DISPERSION ANALYSIS TYPE
DRAWBACKS

TRAM LINE THINKING

LESS CREATIVE

1 41
 Production Process
Classification Type

Cause & Effect Diagram

 PRODUCTION PROCESS
CLASSIFICATION TYPE
In this type, we draw the high level flow diagram for the
process concern to the problem. Then in each process try
to identify the Causes/sub causes/sub-sub causes

1 43
 IDENTIFICATION OF CAUSES
Royal
PRODUCTION PROCESS CLASSIFICATION TYPE QC
C & E DIAGRAM

HIGH
OPEN BATH & HOSPITAL
LAUNDRY WATER
WASH AREA PREMISES
CONSUMPTION
 DEFEAT
IN
Practice & Strategic Application
Selection Conditioning Planning
CRICKET
TEST
MATCH

Here we have selected the process as

‘Selection’, ‘Practice & conditioning’,
‘Strategic planning’ & ‘Application’.
 Like in dispersion method
here also you can go step by
step I.e. taking ‘selection’ first
and finding out main causes
for it. Then by questioning
find out the sub causes, sub-
sub causes, sub-sub-sub
causes and so on.
 Improper ratio of Deserving players
Batsmen & Bowlers not selected

Regional
politics No proper
Lack of foresight selection method
Few players
Captain & team having fitness No
not consulted problems professional
consulted

SELECTION
Tracks do not
help pacers

Not enough fast

bowlers in India

Not enough pace

academies
Not enough Fast
bowlers in team
 Outdated conditioning
Not enough practice
methods

Very tight
schedule
No cricket
Not enough time to Lack of academies
practice professionals
Lack of funds
Team announced
very late
PRACTICE &
CONDITIONING
No due importance given
No professional
consulted
Inadequate fielding practice
Only one ccach

No professional Not many good coaches

Fielding coach
No specialized
coaching
 No game plan to
No basic strategy
play fast bowling
No professional
Veterans not consulted
consulted
No time to
prepare Players do not
Lack of contribute
professional help
ego hassles

STRATEGIC PLANNING

Lack of videos

Players not
Lack of No due importance
interested
professional given to fielding
help

Batsmen not Fielders not

studied studied
 Bad batting Bad bowling
Flat track
No specialist openers
Not enough seamers
Spinners not
Main batsmen Inadequate effective
exposed to pace attack
new ball Main bowlers unfit
Lack of tech. Not enough
Irresponsible shots to play experience
pacers
No instruction from captain Bad team selection

APPLICATION
Lack of practice immature
Batsmen not studied
Dropped catches Improper field placement
No specialist slip fielders Bad field Not respected
Lack of practice placement

Misfieding Bowlers not consulted Captain cannot motivate

No specialist fielders

Bad fielding Bad Captaincy

Cause Enumeration Type
Cause & Effect Diagram
 Third type is 'Cause Enumeration Type'.
Here we write the problem i.e. defeat in
'Cricket Test Match' and do a brainstorming
without any restriction.
 Here once the
brainstorming is over after
eliminating superfluous and
irrelevant causes, based on
discussion we have to
organise the remaining
causes in an orderly
manner.
That means arranging them as Main Cause,
sub-causes, sub-sub causes and so an. The
resultant diagram may look like the cause
dispersion type but the method adopted is
different.
IMPORTANT POINTS TO REMEMBER
AFTER MAKING A

CAUSE AND EFFECT DIAGRAM

 MAIN
EFFECT
CAUSE

SUB-SUB- SUB
SUB-SUB
SUB
CAUSE CAUSE
CAUSE

We can find a logical relationship

through the sub-sub-sub causes to the
final effect.
 probable causes of unhealthy working environment at Bio-
Table 5.1

K. Banerjee A. Manna sludge

A. Ghosh handling area A. Bhandari
K. Pradhan C. Maity
Rainy water
Drier chute line Improper polymer Hydraulic lifter
ingress to sludge Drier feed high Lack of awareness
choking dosing breakdown
bag

Improper Bed smell from Sludge filled bag PTA powder Frock lift Improper FOS
sampling scrubber out tilted laying inside bag unavailability dosing

Sludge bag kept Miss- Bad quality of Drier Steam leakage Truck Drier area
at open place Communication out sludge from Drier paddle unavailability cleaning by IW
Sludge feed
Improper floor Frequently bag Staircase slopping
variation into Miss-operation Working in hurry
slopping change over problem
drier

Improper sludge Open ditch at Improper Improper scrubber Sludge fallen on

Bad road condition
bag storing drier area Patrolling draining ground

Vapour cloud at MLSS high in Slippery floor at

PASS PASS PASS
Drier area WWT bag changing area
PASS PASS PASS PASS PASS PASS
PASS PASS PASS PASS PASS PASS
Each member gave opinion one by one & opinion sharing continued till
two successive “pass” came from each member. 57
 SUMMARY
Cause and Effect Diagrams are:-
* Orderly arrangement of theories.
* Must be consistent with logical
causal relationships.
* Helpful in guiding further enquiry
and testing.
* Not a substitute for data.
 Mr. C. Maity Mr. A. Bhandari Mr. K. Banerjee

Mr. A. Ghosh Mr. A. Manna

Whole Group

Cause Enumeration
Fig 5.1.

Mr. K. K. Pradhan
Method : given opinion one by one & finally 61
prepared with all members
62
 CAUSE ENUMERATION TYPE
Step-1 In this type of cause and effect diagram
first causes are identified, then stratified based
on their affinity then for each group headers are
decided.

1 63
 CAUSE ENUMERATION TYPE
Step-2 In each header, whatever causes are mentioned
to be checked as they are independent cause or the sub
cause of any cause. Set them causes/sub causes/sub
causes wise for all the headers and make cause and effect

diagram in a big sheet.

1 64
CAUSE ENUMERATION TYPE
Step-3 See each cause and try to apply why-why in each.
Make a proper C&E diagram in big sheet. Display it to
the problem area for a week with a request “pl note down
any cause left “ During week, whatever additional causes
noted by the employees to be incorporated in the C&E
diagram.

1 65
CAUSE ENUMERATION TYPE
PROCESS OF MAKING CAUSE AND EFFECT DIAGRAM

1. Go for round robin method and collect the causes as

many as group can.
2. One member among the team will note down the
causes given by the members.
3. For noting the causes, use one cause in one slip. (Pl
note, this is not slip method as you are using round robin
method).

1 66
CAUSE ENUMERATION TYPE
PROCESS OF MAKING CAUSE AND EFFECT DIAGRAM

4. Once all the possible causes are noted by the group,

any two member should take the slips and stratify them
affinity wise. Don’t keep in mind any header, that will be
decided after seeing the affinity.
5. Decide the header.
6. Re set the slips on cause/sub cause wise.

1 67
CAUSE ENUMERATION TYPE
PROCESS OF MAKING CAUSE AND EFFECT DIAGRAM

4. Once all the possible causes are noted by the group,

any two member should take the slips and stratify them
affinity wise. Don’t keep in mind any header, that will be
decided after seeing the affinity.
5. Decide the header.
6. Re set the slips on cause/sub cause wise.

1 68
 PROBABLE ROOT CAUSES
1.…………………… 12…………………..
2…………………… 13…………………..
3…………………… 14…………………..
4…………………… 15…………………..
5…………………… 16……………………
6…………………… 17……………………
7…………………… 18……………………
8………………….. 19……………………
9…………………… 20……………………
10………………….. 21……………………
11………………….. 22…………………….
DATA ANALYSIS
Collect the past data for the root causes
or collect the present data if possible
otherwise go for opinion pole with the
concern person. If required, make the
Pareto Diagram

1 73
 METHOD Improper NO DRAWING
Piston cone
NO DRAWING Improper heat Taper
No
treatment No gauge
fixture
Improper Ring Lacking

1s s
Improper

t ta
No

2nd
No gauge No gauge Anodizin
3r

checking
d

Improper g
sta

fixture

sta

ge
Eccentric Improper assembly
Piston
Assembling
ge

ge
Graphite Of piston rings
Improper clearance
Piston Peel off
Piston Piston Why?
Cone
Cone TDC where
Setting
setting Not
Not
correct Improper piston assembly
correct

NO DRAWING
Where?
No setting
No proper No fixture
220c manual
washing m/c.
Not able to WHERE? WHY? Improper
With stand assembling
Temp. crank case

Inferior Pressure not

Parts clg. Washing OIL MELTING
unsatisfactory Grade oil Developed in
30 mts, in 150 cb
 Pressure not
Developed in
No safety device Improper chemical hardness 30mts. In 150 CB
RUNNING
Improper method TEST
Over heating of dert
Cylinder low Wrong alloy
No drawing Testing hardness
Incorrect hydraulic fixture Inferior varnish
CYLINDER BUCKLES

UNABLE TO Date expired

WITH STAND
AT 22oC No specn.

No temp. calibr
No drawing
Incorrect performance testing ation on furnace
Cylinder
And sleeve
In correct fixture Jointleak

No Drawing

MATERIAL Improper press fitting

 %y fhuzq;fis fz;lwpjy;
LC100 Ngy;gpsf;fh; gpNshz;NlhNkl; kpd;rhu
kpd;rhu nryT mjpfk; nryT mjpfk;

xNu fhh;bq; iydpw;F ,uz;L

gQ;R fhh;bq; nk~pDf;F
GNsh&k; XLtjhy;
Njit ,y;yhj NghJk; gPl;lh;
XLtjhy;

igg; iyd; trjp ,y;yhjjhy;

kp~pd; tbtikg;G

kpd;rhu
nryT
mjpfk;

76/60
];gpd;dpq; nk~pd; kpd;rhu nryT OHTC kpd;rhu nryT mjpfk;
mjpfk;

];gpd;dpq; Ngd;Nkhl;lhh; Unit

mjpfkhf ,Ug;gjhy; nk~pd; fpspdpq;w;F Njitf;F
mjpfkhd gpu];]h; ,Ug;gjhy;

XNu ];gPby; XLtjhy;

Gpu];]Uf;F jFe;jthW ];gPil khw;w

Kbahjjhy; kpd;rhu
nryT
mjpfk;

77/60
 Ml;NlhNfhzh; kpd;rhu fhh;bq;fpy; kpd;rhu nryT mjpfk;
nryT mjpfk;

fhh;bq; njhlh;e;J XLtjhy;

rf;rd; Nkhl;lhh; Unit mjpfkhf
nryT Mtjhy;
mLj;j bghh;l;nkz;l;bw;F Njitahd cw;gj;jp
fpilf;fhjjhy;
Inverter Frequency setting
mjpfkhf ,Ug;gjhy;;
fhh;bq;fpy; HANK igdh;
Mf ,Ug;gjhy;
fTz;l;bw;F jFe;jthW
nrl;bq; ,y;yhjjhy;
kpd;rhu
nryT
mjpfk;

78/60
 780 VXL gpy;lh; kpd;rhu nryT mjpfk;
hPypq; M/Cfspy; kpd;rhu
nryT mjpfk;

nrd;l;hpgpfy; Ngd; Nkhl;lhh; Unit mjpfk;

epw;Fk; nk~pd;fspd; biut; rhg;l;fSk;
XLtjhy;
Njitf;F mjpfkhd Vh; gpu];]h; ,Ug;gjhy;

xNu Nkhl;lhHpy; midj;J hPypq;

M/C;fSk; XLtjhy;
nk~pd; gioa khlyhf ,Ug;gjhy;

ADAD

79/60
 CAUSE & EFFECT DIAGRAM ( fhuz tpisTr; rpj;jpuk; )
];lhg;gh; nrl;bq; rhpapy;yhik Suction Mouth Comp y; Dust ,Ug;gjhy;

Cradle nrl;bq; khWtjhy;

Nfhzpy; ,Ue;J ,io xJq;Ftjhy;

Rh Bearing Drum y; cuRtjhy;

Suction Mouth
Nfhzpy; ,Ue;J ,io vLf;fhik
Empty Tube Vaibriation Mtjhy;
MUP FAULT tUjy;
PC FAULT tUtjhy; Low
,ae;jpuk; EffIciency
Drum
Retie Pipe Position khWtjhy;
Drum Cover Bend Mf ,Ug;gjhy;

Retie Pipe fz;by; ,Ue;J ,ioia vLf;fhik Suction Mouth Drum Cover y; jl;Ltjhy;

Splicer y; Ehiy Splicing nra;aahik

Sand Paper cwptjhy;

MSL FAULT tUjy; MUP FAULT tUjy;

80#
 CAUSE & EFFECT DIAGRAM ( fhuz tpisTr; rpj;jpuk; )
Uster Quantum Sensor Sensing Mfhjjhy;
Pho Sensor y; Waste ,Ug;gjhy;

Yarn y; Breakage mjpfkhf tUtjhy;

Nkf[pd; Rw;whik

Uster Quantum Trouble Mtjhy;

Cop Change Mfhjjhy;
Uster Quantum Ntiy nra;ahik
B 1 FAULT tUtjhy;
C 4 FAULT tUtjhy; Low
,ae;jpuk; EffIciency
Pho Sensor y; NkYk; fPYk; Cover ,Ug;gjhy; Drum

Pho Sensor y; Waste ,Ug;gjhy;

Pho Sensor y;Yarn Sensing Mfhjjhy;

rhpahf Splicing Mfhjjhy;

MSL& T.B FAULT tUjy;

81#
 CAUSE & EFFECT DIAGRAM ( fhuz tpisTr; rpj;jpuk; )
Kink Priventer Brush Ntiy nra;ahjjhy;
Clamb y; cs;s O Ring Damage
Retie Pipe Duct y; Nt];l; milg;gjhy;
Mf ,Ug;gjhy;

Retie Pipe y; ,Ue;J Vh; Fiwthf tUtjhy;

Splicer y; Clamp Ehiy rhpahf gpbf;fhik

Retie Pipe ,ioia vLf;fhik

Splicer y; Splicing Ehy; tpyFtjhy;
M.S.L FAULT tUtjhy;
MSL FAULT tUjy; Low
nghUs; EffIciency
Drum
Uster Quantum Cutter Nja;e;jpUg;gjhy;

Uster Quantum Cutter Ntiy nra;ahjjhy;

Uster Quantum Cutter Yarn ia Cut nra;ahik

C 3 FAULT tUtjhy;
82#
 CAUSE & EFFECT DIAGRAM ( fhuz tpisTr; rpj;jpuk; )
Kink Priventer Brush Ntiy nra;ahjjhy;
Clamb y; cs;s O Ring Damage
Retie Pipe Duct y; Nt];l; milg;gjhy;
Mf ,Ug;gjhy;

Retie Pipe y; ,Ue;J Vh; Fiwthf tUtjhy;

Splicer y; Clamp Ehiy rhpahf gpbf;fhik

Retie Pipe ,ioia vLf;fhik

Splicer y; Splicing Ehy; tpyFtjhy;
M.S.L FAULT tUtjhy;
MSL FAULT tUjy; Low
nghUs; EffIciency
Drum
Uster Quantum Cutter Nja;e;jpUg;gjhy;

Uster Quantum Cutter Ntiy nra;ahjjhy;

Uster Quantum Cutter Yarn ia Cut nra;ahik

C 3 FAULT tUtjhy;
83#
 CAUSE & EFFECT DIAGRAM ( fhuz tpisTr; rpj;jpuk; )
];lhg;gh; nrl;bq; rhpapy;yhik

Cradle Vibration Mtjhy;

Uster Quantum j;jpy; Waste ,Ug;gjhy;

Yarn Uster Sensor y; Jump Mtjhy;

Splicing Yarn Dia Meter mjpfkhf ,Ug;gjhy;
Uster Trouble Mtjhy;
Uster Quantum j;jpy; Splicing Yarn Cut Mtjhy;
C 4 FAULT tUtjhy;
MSM & T.B FAULT tUjy;
Low
nra;Kiw EffIciency
Drum
Uster Cutter Plate Screw Loose Mf ,Ug;gjhy;

Uster Cutter Plate jl;b epw;gjhy;

Uster Cutter Yern ia Cut nra;ahik

C 3 FAULT tUtjhy;
84#
 CAUSE & EFFECT DIAGRAM (validation)

,ae;jpuk;

PHO Sensor y; Waste ,Ug;gjhy; YES

Retie Pipe Position khWtjhy; YES

YES Stopper Setting

khWtjhy; Low
Efficiency Drum

CAUSES MEASURE VALID / UNVALID

PHO Sensor y; Waste ,Ug;gjhy; GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

;

GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

Retie Pipe Position khWtjhy;

Stopper Setting khWtjhy;

GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ
85#
 CAUSE & EFFECT DIAGRAM (validation)

nghUs;

Ntiy
Kink Priventer Brush YES

nra;ahjjhy;
Splicer “O” Ring NlNk[; Mtjhy; YES

YES Uster Quantum Cutter

Wornout
Low
Efficiency Drum

CAUSES MEASURE VALID / UNVALID

Kink Priventer Brush Ntiy nra;ahjjhy; GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

Splicer “O” Ring NlNk[; Mtjhy; GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

Uster Quantum Cutter Wornout
86#
 CAUSE & EFFECT DIAGRAM (validation)

nra;Kiw
kdpjd;
Uster Cutter Plate Screw Loose YES
Mf ,Ug;gjhy;

Uster Quantum j;jpy; Waste ,Ug;gjhy; YES

NO Cop ia
rhpahf
cUtp Nghlhik
Low
Efficiency Drum

CAUSES MUEASERE VALID / UNVALID

Uster Cutter Plate Screw Loose GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

Mf ,Ug;gjhy;

Uster Quantum j;jpy; Waste ,Ug;gjhy; GEMBA SURVEY Vw;Wf;nfhs;sg;gl;lJ

Cop ia rhpahf cUtp Nghlhik GEMBA SURVEY epuhfhpf;fg;gl;lJ

87#