Written by: Shobhit Jindal
In our industry, “Root Cause Analysis” (RCA) is used like a buzzword in every production meeting, especially after something goes wrong. A shipment was late? A buyer rejected a shipment? Start an RCA. But here’s the problem:
In factories, we often use root cause analysis as a formality, not to truly solve the problem. And when that happens, the same defect returns. The same machine stops. The same chaos continues.
Let’s explore why RCA often fails — and how you can fix it, with real examples from the floor.
1. Blaming the Operator Is Too Easy
The Problem:
Line 3 has repeated seam puckering at the armhole. The supervisor says, “The operator is inexperienced or new.” RCA done? Not quite.
The Real Fix:
Ask “Why?” a few more times:
Why did puckering happen? → Because the seam wasn’t flat.
Why? → Because the feed dog and presser foot weren’t synchronized.
Why? → The machine setting was wrong for that fabric.
Why? → There was no machine setting guideline for this fabric type.
Root Cause: Lack of machine setting SOPs for lightweight fabrics.
Action Plan: Create and display machine setting guides by fabric type.
2. Treating the Symptom, Not the Process
The Problem:
A shipment gets delayed because the printing department didn’t finish on time. The factory adds another printer.
The Real Fix:
Hold on — was capacity really the problem? Look deeper:
Why was printing delayed? → Because some panels were rejected for misalignment.
Why? → Because one of the frames wasn’t aligned after the last design change.
Why? → There was no standardized setup checklist post-design change.
Root Cause: No printing alignment SOP after design changes.
Action Plan: Standardize print frame setup steps with visual checks.
3. Skipping the Gemba (Factory Floor)
The Problem:
QC reports show high sleeve attach alignment problem. Management holds a meeting in the conference room and decides to change the operator or even checker.
The Real Fix:
- Walk to the floor. Observe. You might find:
- Sleeve alignment is not correct, or
- The marker has the wrong notch positions.
Root Cause: Mismatch between the pattern notch and the sewing marker.
Fix: Update the marker with correct notches.
RCA isn’t a desk job. Real answers come from the floor.
RELATED POST | Finding Root Causes of Quality Issues using Root Cause Analysis Method
4. Using Fancy Tools with No Clarity
The Problem:
Some teams create beautiful fishbone diagrams with 20 causes, but no clear conclusion.
The Real Fix:
Focus on clarity, not complexity. Example:
Problem: Shade variation in garment.
Observation: Shading appears on left panel across.
Investigation: All affected panels cut from end of roll.
Root Cause: No fabric shade segregation before cutting.
Fix: Introduce fabric shade grouping and ticketing system.
Sometimes, a simple check sheet and photo evidence solve more than fancy charts.
5. No Follow-Up = No Change
The Problem:
After RCA, a corrective action is implemented… but never reviewed.
Result: The defect reappears few days later in a different line.
The Real Fix:
Build a feedback loop:
Review defect trends after 1 week, 2 weeks, 1 month.
Interview floor staff: Did the new process help?
Update training modules and visual aids if needed.
RCA isn’t done when the meeting ends. It’s done when the problem stops recurring.
Final Takeaway: RCA = Real Change Action
If you’re a student doing your first project in a garment unit, or a IE/QA just starting out — remember:
👉 Don’t settle for surface-level causes.
👉 Talk to operators, check machines, look at real pieces.
👉 Always validate your fix with results.
Root Cause Analysis is more than a tool — it’s a mindset. If you get it right, you won’t just solve problems. You’ll build trust, improve processes, and save serious money.
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