Learn the steps to troubleshoot and solve any failure in food manufacturing. Find out how to gather and analyze data, test hypotheses, implement solutions, and review outcomes.

Some tools stand the test of time. The Ishikawa diagram, and asking why 5 times generally gets to the bottom of the problem and for good reason. However, the caveat is to ensure that you are collecting objective data in relation to the problem. Too often I’ve seen data collected trying to prove someone’s theory. It can send you down side tracks and wastes time.

You're struggling to identify the root cause of a failure. What steps should you take?

When something goes wrong in food manufacturing, you need to find out why and fix it as soon as possible. But sometimes, the cause of a failure is not obvious or easy to pinpoint. You may have multiple factors, complex interactions, or hidden defects that contribute to the problem. How can you identify the root cause of a failure and prevent it from happening again? Here are some steps you can take to troubleshoot and solve any issue in food manufacturing.

1 Gather data

The first step is to collect as much data as possible about the failure. Data can include production records, quality reports, customer feedback, equipment logs, environmental conditions, and any other relevant information. You can use tools like checklists, charts, graphs, and tables to organize and visualize the data. The more data you have, the better you can understand the scope, severity, and frequency of the failure.

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Neil Almond

Quality & Regulatory Director | Available from February | Board Director | Consultant | Creating solutions to safeguard brands, supply chains and businesses through change | PGCE | NQT | Secondary Maths Tutor
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Some tools stand the test of time. The Ishikawa diagram, and asking why 5 times generally gets to the bottom of the problem and for good reason. However, the caveat is to ensure that you are collecting objective data in relation to the problem. Too often I’ve seen data collected trying to prove someone’s theory. It can send you down side tracks and wastes time.

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2 Analyze data

The next step is to analyze the data and look for patterns, trends, and anomalies. You can use techniques like Pareto analysis, scatter plots, and histograms to identify the most significant or frequent causes of the failure. You can also use tools like fishbone diagrams, 5 whys, and fault tree analysis to explore the possible causes and effects of the failure. The goal is to narrow down the list of potential causes and focus on the ones that have the most impact or influence on the failure.

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3 Test hypotheses

The third step is to test your hypotheses and verify the root cause of the failure. You can use methods like experiments, simulations, or trials to test the effects of different variables or factors on the failure. You can also use tools like statistical process control, design of experiments, and hypothesis testing to measure and compare the results. The aim is to confirm or reject your hypotheses and find the cause that best explains the failure.

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4 Implement solutions

The fourth step is to implement solutions and prevent the failure from recurring. You can use techniques like brainstorming, benchmarking, and best practices to generate and evaluate possible solutions. You can also use tools like action plans, PDCA cycles, and FMEA to plan, execute, monitor, and improve your solutions. The objective is to eliminate or reduce the root cause of the failure and improve the quality and performance of your process.

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5 Review outcomes

The final step is to review the outcomes and assess the effectiveness of your solutions. You can use metrics like yield, defect rate, customer satisfaction, and cost savings to measure and quantify the outcomes. You can also use tools like feedback surveys, audits, and reviews to collect and analyze the feedback. The purpose is to verify that your solutions have solved the problem and achieved the desired goals.

Troubleshooting and solving failures in food manufacturing can be challenging, but not impossible. By following these steps, you can identify the root cause of any failure and implement effective solutions. This will help you improve your product quality, customer satisfaction, and profitability.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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You're struggling to identify the root cause of a failure. What steps should you take?

1

2

3

4

5

6

1 Gather data

2 Analyze data

3 Test hypotheses

4 Implement solutions

5 Review outcomes

6 Here’s what else to consider

Food Manufacturing

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You're struggling to identify the root cause of a failure. What steps should you take?

1

2

3

4

5

6

1 Gather data

2 Analyze data

3 Test hypotheses

4 Implement solutions

5 Review outcomes

6 Here’s what else to consider

Food Manufacturing

Rate this article

Thanks for your feedback

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