AS9100 Root Cause Analysis

Root Cause Analysis (RCA) is a systematic process used to identify the underlying causes of problems or incidents, including those related to AS9100 – an aerospace quality management system standard. RCA is important for organizations in the aerospace industry because it helps prevent the recurrence of issues, ensuring safety, and improving overall product quality. Here are the steps to perform a Root Cause Analysis for AS9100:

1. Define the problem: Clearly state the issue or non-conformance identified in the AS9100 audit, making sure to include all relevant information such as the date, location, personnel involved, and the specific AS9100 requirement that was violated.
2. Gather data: Collect all available information related to the problem. This may include documentation, records, photographs, interviews with personnel, and any other relevant evidence.
3. Timeline of events: Develop a detailed timeline of the events leading up to the problem. This helps in identifying when and where the issue first occurred and helps to narrow down potential causes.
4. Identify possible causes: List all possible causes for the issue, without filtering or prioritizing them. Consider all contributing factors, such as human error, process failures, equipment malfunction, or management shortcomings.
5. Root cause identification: Using techniques like the 5 Whys, Fishbone Diagram (Ishikawa), or Fault Tree Analysis, systematically evaluate each potential cause and determine the root cause(s) of the problem. The root cause is the underlying issue that, if addressed, will prevent the problem from recurring.
6. Develop corrective actions: Develop appropriate corrective actions to address the root cause(s) identified. These actions should be specific, measurable, achievable, realistic, and time-bound (SMART).
7. Implement corrective actions: Assign responsibility for implementing the corrective actions and establish a timeline for completion. Monitor the progress and ensure that the actions are effectively implemented.
8. Verify effectiveness: After the corrective actions have been implemented, monitor the situation to ensure that the problem does not reoccur. Evaluate the effectiveness of the corrective actions and make adjustments as necessary.
9. Update documentation: Update relevant AS9100 documentation, such as procedures, work instructions, or training materials, to reflect any changes made during the RCA process.
10. Communicate findings: Share the results of the RCA and the corrective actions taken with relevant stakeholders. This may include employees, management, customers, and regulatory authorities, as appropriate.

By following these steps, organizations can effectively conduct a Root Cause Analysis in line with AS9100 requirements, ultimately improving product quality and safety in the aerospace industry.