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Workshop 04 1–2 days per problem Workshop + live coaching

Root Cause Analysis Sessions

If the same problem keeps showing up, you haven't solved it yet.

Stop firefighting symptoms. Get to the real cause so problems stop coming back.

5 Whys

to move from symptom to true root cause

70%

of recurring issues trace to fewer than 3 causes

1

A3 your team can reuse on every future problem

The real story

Most 'solutions' fail because the team never agreed on the actual problem. RCA forces clarity — and once a team experiences a problem that finally stays solved, the methodology sells itself.

By the numbers

More of what this workshop unlocks

80%

fewer recurrences when causes are verified, not guessed

3 tools

5 Whys, Fishbone, Pareto — taught and applied live

1 page

A3 captures the whole problem, end to end

See examples from past work

What this looks like in the real world

An anonymized snapshot from a recent engagement. Names and identifying details changed — outcomes and methodology are real.

Case vignetteMedical device supplier
The challenge
A field-return defect kept reappearing despite three previous 'fixes' and a corrective action backlog.
What we did
Two-day structured RCA session using 5 Whys and Fishbone with engineering and quality side by side.
The result
Identified two verified causes nobody had tested before. Recurrence dropped from monthly to zero across the next two quarters.

Roles in the room

  • Quality Director (sponsor)
  • Design engineer
  • Process engineer
  • Quality engineer
  • Customer service lead

Timeline

  1. 1

    Data & returns review

    Week 1

  2. 2

    RCA workshop

    Days 1–2

  3. 3

    Counter-measure pilot

    Weeks 2–6

  4. 4

    Verification window

    Months 2–6

Anonymized data

3

Prior 'fixes' attempted

2

Verified root causes

Monthly

Recurrence (before)

0

Recurrence (after, 6 mo)

Figures rounded and lightly anonymized to protect client identity.

Headline outcome

100% recurrence eliminated

Could your team see a result like this? The only way to know is a 30-minute conversation about your process.

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Same workshop, digital environment

What this looks like in a corporate / digital team

The exact same methodology — applied to software, SaaS, IT, marketing, or professional-services workflows. Anonymized snapshot from a recent engagement.

Digital exampleSaaS Platform — Recurring P1 Incidents
The challenge
A multi-tenant SaaS kept hitting the same database-connection P1 every 3–4 weeks. Three postmortems, three 'fixes,' same incident.
What we did
Two-day RCA session with SRE, platform engineering, and the on-call lead. Used 5 Whys + Fishbone against the incident timeline data.
The result
Found two verified causes nobody had tested: a connection-pool config + a silent retry storm in a sidecar. Recurrence stopped cold.

Headline outcome

0 P1s in next 2 quarters

Same DMAIC, RCA, mapping, and standard-work tools — applied to digital workflows like Jira, Salesforce, HubSpot, GitHub, Asana, and Notion.

Annualized savings

~$540K / yr

6 P1s avoided × ~$65K blended cost per incident (engineering response, SLA credits, and at-risk renewal exposure) plus −88% MTTR on the related class.

Why this workshop matters

When the same problem keeps returning, the team is solving symptoms — not causes. Structured root cause analysis using 5 Whys, Fishbone, and Pareto helps teams find and fix what's actually broken.

What your team walks away with

  • Verified root causes — not assumptions
  • Counter-measures linked directly to causes
  • A documented A3 or problem-solving record
  • Reduced recurrence of the targeted problem

Up next

DMAIC Project Coaching

Proof across industries

Outcomes from 5 different industries

Anonymized snapshots from real engagements. Filter by industry or outcome type to focus on the proof that matters most to you.

Filter
Anonymized proof Medical device supplier

The team walked in skeptical and walked out with a working improvement and a control plan to keep the gain.

Engagement sponsor, Medical device supplier

Root Cause Analysis Sessions

Outcome

100% recurrence eliminated

Headline outcome from a recent engagement

Identifying details changed. Methodology and results are real.

Anonymized proof B2B SaaS

We thought our velocity problem was a hiring problem. Two hours mapping our sprint workflow proved it was a meeting and review-queue problem.

VP of Engineering, B2B SaaS

Process MappingEngineering Ops

Outcome

+18%

Story-point throughput in 60 days

Identifying details changed. Methodology and results are real.

Anonymized proof Enterprise IT / Cloud

Coaching pulled 14 stalled FinOps and reliability projects across the line. Finance signed off on every dollar, and our P2 incident count dropped by a third.

Director of Cloud Engineering, Enterprise IT / Cloud

DMAICFinOps

Outcome

$1.1M

Validated cloud cost savings

Identifying details changed. Methodology and results are real.

Anonymized proof Consumer Goods Manufacturing

Daily huddles changed the cadence of the entire plant. Issues that used to die in monthly reports get solved by lunch.

Plant Manager, Consumer Goods Manufacturing

Daily ManagementOpEx

Outcome

+11pt

OEE improvement, no capex

Identifying details changed. Methodology and results are real.

Anonymized proof Distribution & Logistics

Two hours of waste-walking surfaced months of buried problems. Overtime was down inside 60 days.

DC General Manager, Distribution & Logistics

Waste WalkFrontline

Outcome

−28%

Overtime reduction in 60 days

Identifying details changed. Methodology and results are real.

Get an outcome like the one above

Drop your name and email — we'll schedule a free 30-minute consultation.

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Common questions

Everything you'd ask before booking

Specific to Root Cause Analysis Sessions — scheduling, format, prerequisites, and what to expect.

  • No prior certification is required. Root Cause Analysis Sessions is built so anyone in the room — from frontline operators to senior leaders — can contribute on day one. We meet your team at their current level and build from there.

  • Standard duration is 1–2 days per problem. Schedules are flexible — full days, half-days, or split across weeks to fit your operations. We finalize the cadence with your sponsor before booking so it works around real production and staffing constraints.

  • Yes — delivery is workshop + live coaching. Onsite is best when the work is physical or floor-walks add value. Remote works well for office, knowledge, and multi-site teams. Hybrid (a facilitator onsite plus remote breakouts) is increasingly common for distributed organizations.

  • Quality teams, Engineering, Operations get the most out of it. We strongly recommend including an executive sponsor for the kickoff and close-out — alignment at that level is what turns workshop output into real change.

  • Most teams identify quick wins during the workshop itself and deliver verified root causes — not assumptions within 30–90 days. Larger structural improvements typically land within one to two quarters once the control plan is in place.

  • Yes. Every engagement starts with a short scoping call to tailor examples, exercises, and templates to your industry, your terminology, and the specific processes you want to improve. Generic case studies don't make it into the room.

  • Facilitation by a Master Black Belt, all materials and templates, a documented output (current-state map, charter, A3, or control plan depending on the workshop), and a 30/60/90-day follow-through plan. We can also bundle coaching for project leaders if you want execution support.

  • Typical cohorts run 8–20 people for hands-on workshops and up to 30 for training-style sessions. Smaller groups go deeper; larger groups build wider capability. We'll recommend a size based on your goal during the consultation.

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