Imagine you're a production or quality manager in a confectionary that makes your favourite chocolate bars. One day, something goes wrong, and the chocolates don't taste quite right.
How would you find out what went wrong? That's where Ishikawa Diagrams can help you.
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What is an Ishikawa Diagram Used For?
The Ishikawa diagram, also known as the fishbone diagram, is a tool that helps us solve problems by looking at all the possible causes and how they relate. As a manager, you become a detective, but instead of solving mysteries, we solve problems in making things.
What is an Ishikawa Diagram?
An Ishikawa diagram is a way to show different ideas about why something happened, all leading back to one main problem, just like bones in a fish lead back to the spine.
It helps people think about all the different parts of a problem, from the materials used to the way people work.
Let's see how big companies that make food, like chocolate bars, use Ishikawa diagrams to keep their products yummy and safe. Because these diagrams can really help you find out what went wrong and how to fix it.
We'll use real-life examples from large food producers and show you step-by-step how an Ishikawa diagram can turn a problem into a solution, keeping everything from getting mixed up!
Solving the puzzle of production problems
Have you ever wondered why sometimes your favourite snack tastes a bit off, or why there might be fewer chips in the packet than usual? Big food companies use many special tools such as food safety inspection software and techniques to solve these mysteries!
In large food production, you can use a visual inspection tool like Inspectle to easily register non-conformities and make sure you are compliant. But on top of that, the Ishikawa diagram is a master key that unlocks the reasons behind quality issues, taste differences, or safety concerns. The diagram can answer the question "Why?" something is happening.
It's particularly helpful when the problem is not obvious. For instance, if a batch of cookies comes out too crunchy, the diagram helps trace back through different possible causes—like ingredients, oven temperature, or even the humidity in the air on the day they were made.
Benefits of Using Ishikawa Diagrams:
Clear Understanding: It helps everyone in the company see the problem clearly and understand how different factors combine to cause it.
Better Communication: It makes it easier for teams to work together and discuss their ideas about what might be going wrong.
Effective Solutions: By understanding all the parts of a problem, companies can make better changes to fix it and stop it from happening again.
Large-scale food producers often rely on tools like the Ishikawa diagram (also known as the fishbone diagram) for root cause analysis, as they provide a structured way to brainstorm potential causes of problems and identify the root issue.
By mapping out factors such as materials, methods, machines, manpower, and environment, companies can get a clearer picture of what’s going wrong, leading to faster solutions.
How to create an Ishikawa Diagram
Let’s say you're running a big bakery, and suddenly, your factory is producing biscuits that are too dry. You’ve tried everything, but the issue keeps coming back. This is where an Ishikawa diagram becomes your best friend!
Creating an Ishikawa diagram isn’t complicated, and once you get the hang of it, it can help solve tricky problems that seem to have no clear solution.
Step-by-Step Guide to Creating an Ishikawa Diagram
Define the Problem: Begin by writing down the specific issue you're trying to solve. In our example, let’s say the problem is "Biscuits too dry." This problem will go at the head of the diagram (the fish's head).
Identify Major Causes: Now, think about the main categories that might be causing this issue. In food production, common categories include:
Materials: The ingredients used in the biscuits, such as flour or butter.
Methods: The way the biscuits are baked, like the oven temperature or baking time.
Machines: Any equipment used during the process, such as ovens or mixers.
Manpower: The people involved, from the bakers to the quality control staff.
Environment: External factors like humidity or the cleanliness of the production area.
These categories form the main bones of the fish, leading to the head.
Brainstorm Possible Causes: With the main categories in place, now think about possible causes within each category. For example, under "Materials," maybe the flour is too old or has been stored improperly. Under "Machines," perhaps the oven temperature is not being properly maintained.
Drill Down Deeper: For each possible cause, continue asking "why" to uncover more specific reasons. For example, if the oven temperature is inconsistent, ask why this is happening. Maybe the thermostat is broken, or perhaps it hasn't been calibrated recently. Each answer becomes a smaller bone branching off from the main cause.
Analyse the Diagram: After all the potential causes are laid out, it’s time to analyse the diagram. Look for patterns or causes that appear across multiple categories. In our biscuit example, if both the materials and environment categories suggest that humidity is causing the flour to clump, you might have found your root cause.
Test and Implement Solutions: Once you've identified the root cause, it’s time to test potential solutions. Maybe the factory needs a better storage system for ingredients, or the baking time needs adjusting.
A major food company once faced an issue with their bread coming out undercooked. Using an Ishikawa diagram, they discovered that the ovens weren't heating evenly because the maintenance schedule hadn't been followed. Once they fixed the ovens and established a more rigorous maintenance routine, the bread's quality improved dramatically.
Tools and Software
There are also many digital tools that can help you create Ishikawa diagrams, such as:
SmartDraw: An easy-to-use tool for creating professional diagrams
Lucidchart: Another popular tool that allows teams to collaborate in real-time.
MindManager: A solid mind-mapping tool.
SlideModel's PowerPoint templates: Yes, you can even create these diagrams with PowerPoint!
Detailed analysis of Ishikawa Diagram components
In large food production, each part of the Ishikawa diagram gives us clues about different aspects of production that might need attention.
Materials:
Contaminated Ingredients: If the strawberries used in a product are contaminated, it can lead to food safety issues.
Seasonality of Ingredients: Using seasonal ingredients can affect the consistency and availability of the final product.
Storage and Handling: Poor storage can lead to perishable materials like fruits degrading faster than expected.
Methods:
Production Techniques: Incorrect cooking or brewing times or temperatures can drastically alter the final product’s quality.
Quality Assurance Processes: Lack of proper QA processes or good safety culture can lead to inconsistencies in product quality.
Machines:
Equipment Maintenance: Outdated or poorly maintained machinery can cause production delays and product defects.
Calibration: Incorrect temperature settings on ovens can lead to undercooked or overcooked food items.
Manpower:
Training: Inexperienced employees or those with insufficient training can make mistakes in production.
Workload: Overburdening staff can lead to errors and reduced attention to detail.
Environment:
Work Conditions: A noisy or chaotic work environment can distract workers and lead to mistakes.
Climate Control: Improper climate control in the production area can affect the quality of food products, particularly those sensitive to temperature and humidity.
Example: troubleshooting with Ishikawa Diagrams
Suppose your newly launched granola bars are receiving complaints about being too hard, which is unexpected and troubling. How do you get to the bottom of this issue without guessing? Enter the Ishikawa diagram, your troubleshooting guide!
Using Ishikawa Diagrams for Problem-Solving:
The Ishikawa diagram not only helps identify potential causes but also guides you through a systematic approach to solving production issues in food manufacturing.
Identify the Symptom: Begin with the problem — in this case, "Granola bars are too hard." Place this as the head of your diagram.
Map Out Major Categories: Consider all aspects of production that could influence the hardness of the granola bars:
Materials: Quality of oats or other ingredients.
Methods: Baking time and temperature settings.
Machinery: Mixers or ovens and their operational status.
Manpower: Staff training and expertise.
Environment: Humidity levels in the production area.
Brainstorm Possible Causes: Under each category, list specific factors that could be contributing to the problem. For example, under "Machinery," you might find that ovens are not calibrated correctly, leading to uneven baking.
Analyse and Test Hypotheses: Once you've listed potential causes, test them. Adjust one variable at a time to see if it resolves the issue. This might mean recalibrating the oven or testing a new batch of oats.
Implement Solutions: When you find a cause that fixes the problem, implement that solution across the board. This might involve updating machinery, retraining staff, or switching suppliers.
The final step is to use what you've learned to prevent future issues. This might mean adjusting standard operating procedures or ongoing training for staff based on the lessons learned from using the Ishikawa diagram.
To take your food safety inspections to the next level, consider using Inspectle Food. Our food safety inspection app, helps you save 70% of the time spent on inspections while solving problems four times faster, using real-time visual checks. Try it for free for 30-days.
About the Author: Robert Jakobson
Robert Jakobson has worked in the manufacturing industry since 2010. With over a decade of experience in B2B marketing, he specializes in helping companies improve their operations with software and hardware solutions. His deep knowledge of the industry and passion for technology make him a trusted expert. Robert’s experience ranges from product development to marketing, giving him valuable insights into how businesses can use tools like the Inspectle Food Safety Inspection software to stay compliant and improve their processes.