Quality template

Root Cause Analysis Sheet (6M)

A structured sheet for root cause analysis: a problem statement, possible causes listed under the 6M categories, the evidence checked for each, and whether each cause was verified and is a root cause.

What this template does#

This sheet is a written fishbone analysis. You write a precise problem statement, list possible causes under the six categories (man, machine, material, method, measurement and environment), record the evidence you checked for each, and mark whether the cause was verified and whether it is a root cause.

The method is described in root cause analysis.

When to use it#

  • For repeated defects, failed inspections and customer complaints.
  • In a small team: supervisor, quality, industrial engineering and maintenance.
  • Before opening a CAPA, to make sure the action targets the right cause.

How to complete it#

  1. Write the problem statement with what, where, when and how much.
  2. Brainstorm possible causes in each category. Include causes that seem unlikely; the evidence will rule them out.
  3. Check evidence for each cause: data by machine and operator, observation, measurements, trials.
  4. Mark verified causes only when the evidence supports them.
  5. Choose the root cause or causes that, if removed, would stop the problem.
  6. Use 5 Why to go deeper on a verified cause when needed.

Example rows#

Category Possible cause Evidence checked Verified?
Machine Knife cutting too much on overlock Seam width measured on 20 pieces: 2 mm under spec Yes
Material Fabric fraying Handled cut panels: no unusual fraying No
Man New operator on the operation Operator has run the operation for 6 months No
Method Seam allowance too narrow Pattern allowance matches standard No

Common mistakes#

  • Listing causes without checking evidence.
  • Stopping at the first plausible cause.
  • Blaming operators without asking why the error was possible.

Download formats#

The Excel workbook contains drop-down lists for categories and Yes or No fields. The CSV contains headings only.

Field guide

FieldWhat to enter
Problem statement, team and dateWhat, where, when and how much, written before causes are listed.
CategoryMan, machine, material, method, measurement or environment, chosen from a list.
Possible causeOne possible cause per row.
Evidence checkedWhat was checked to test the cause: data, observation, trial.
Verified and root causeYes or No. Mark verified only when the evidence supports it.

Related guides

Quality & DefectsHow-to3 min read

Root Cause Analysis for Garment Defects: A Practical Method

Repairing defects fixes garments; root cause analysis fixes the process. A step-by-step method for garment factories using defect data, the 5M categories, fishbone diagrams and 5 Why, with a worked example on open seams.

Quality & DefectsHow-to3 min read

5 Why Analysis: Examples from Garment Production

5 Why analysis asks 'why' repeatedly until it reaches a cause that can be fixed. How to use it well, where it goes wrong, and three worked examples from sewing, cutting and finishing.

Quality & DefectsGuide3 min read

CAPA in Garment Factories: Corrective and Preventive Action

CAPA is the process for recording a problem, removing its cause and preventing it elsewhere. What corrective and preventive actions mean, the steps of a CAPA, a filled example, and how to keep CAPAs from becoming paperwork.

Quality & DefectsGuide3 min read

DHU (Defects per Hundred Units): Formula and How to Use It

DHU counts defects per hundred garments checked. The formula, how it differs from defective percentage, a worked example from end-of-line checking, and how to turn DHU data into action on the line.

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