Root Cause Analysis (RCA) is a structured methodology used to identify the true origin of problems, rather than just addressing their symptoms.
In the context of failure screening in production and test engineering, RCA is an essential tool to reduce rework, waste, and prevent defect recurrence.
🛠️ How does RCA work in failure screening?
When a product fails in a test system or shows field failures (RMA, after-sales), it is crucial not only to repair the item but to understand why it failed.
The application of RCA in screening involves:
- Isolation of the actual defect (e.g., electrical failure, assembly error, software issue)
- Systematic data collection (test logs, DUT history, measured parameters, operating environment)
- Structured analysis with tools such as:
- 5 Whys
- Ishikawa Diagram (Fishbone)
- Pareto Analysis
- Validation of the identified cause with additional tests or simulations
- Implementation of corrective and preventive actions to eliminate the cause definitively
🧩 Benefits of applying RCA
| Benefit | Real Impact |
|---|---|
| Elimination of problems at the source | Less rework and increased productivity |
| Reduction of operational costs | Less material and time waste |
| Continuous product improvement | More reliable and durable products |
| Support for ISO/IATF certifications | Solid evidence of effective corrective actions |
| Increased customer satisfaction | Reduction of RMAs and returns |
🛠️ How AJOLLY Testing applies RCA in screening projects
AJOLLY Testing systematically implements RCA in diagnostic and rework processes:
- Complete failure recording at the time of testing
- Analytical dashboards to identify defect patterns
- Structured application of 5 Whys and Pareto analysis
- Consulting for root cause identification in production lines
- Training of screening teams for adopting scientific investigation methods
🎯 When to apply RCA?
- Screening of failed products (OQC, OBA)
- High incidence of failures at the same point (Top Failures)
- Customer returns (RMA)
- After-sales complaints
- Intermittent failures difficult to diagnose
“Fixing a defect is solving a problem. Eliminating the root cause is creating sustainable quality.” — AJOLLY Testing Philosophy