A multinational food processing company that produces a wide variety of private-label packaged foods and employs thousands of workers across 20 different facilities.
According to their director of continuous improvement: "We decided as a company that we were lacking in terms of skill in problem solving and root cause analysis. We would see RCA work done, but it wasn't really thorough enough and we never got at the root causes. We ended up seeing the same problems over and over again. Everyone on the senior operations management team saw this, so there was buy-in right off the bat to find a better solution."
After searching the internet and talking to others about their experience with different problem-solving methodologies, the company selected a few providers to explore further. They saw various demos on different products and services, but ultimately decided to move forward with training in the Apollo Root Cause Analysis methodology and RC Pro™ software from ARMS Reliability. "We thought this methodology was relatively easy to understand and wasn't in any way incongruent with the other methodologies we were already using in our continuous improvement department. A simple version of the Apollo Root Cause Analysis methodology would use a '5 Whys' type of thinking, which we were already using. It took what we were already doing to the next level," said the company representative.
This particular company did six two-day Root Cause Analysis training sessions over the course of six months in addition to purchasing RC Pro™ software. They are still in the early stages of program implementation, so they won't have quantitative metrics on the success of the program for a while yet. However, this customer is already seeing a lot of enthusiasm from his team. "People seem to think it will be a big help. Some people have gone in to training not really knowing why they were there, but coming out of it, a lightbulb goes on - 'if we do this properly this will work.'"