TGM Manager provides a comprehensive Root Cause Analysis system with support for multiple methodologies including 5 Whys and Fishbone diagrams, along with integrated CAPA (Corrective and Preventive Actions) management.

Overview¶

The RCA system supports:

• Multiple Methodologies - 5 Whys, Fishbone (Ishikawa), and hybrid approaches
• Evidence Tracking - Document evidence for each finding
• Risk Scoring - Likelihood and impact assessment for fishbone causes
• CAPA Integration - Create and track corrective/preventive actions
• Task Management - Assign and track CAPA tasks
• Dashboards - Analytics for RCA and CAPA performance

RCA Methodologies¶

RCA Statuses¶

REST API¶

RCA Management¶

Create RCA¶

POST /rca
Content-Type: application/json

{
  "title": "Pump P-101 Bearing Failure Analysis",
  "description": "Investigating recurring bearing failures",
  "methodology": "FIVE_WHYS",
  "problemStatement": "Pump P-101 has experienced 3 bearing failures in the last 6 months"
}

Required Role: ADMIN, MANAGER, or OPERATOR

Create RCA from Event¶

POST /rca/from-event/{eventId}?methodology=FIVE_WHYS

Creates an RCA linked to an existing event record.

Create RCA from Failure¶

POST /rca/from-failure/{failureId}?methodology=FISHBONE

Creates an RCA linked to an existing failure record.

Update RCA Status¶

PATCH /rca/{rcaId}/status?status=IN_PROGRESS

Required Role: ADMIN or MANAGER

Submit for Review¶

POST /rca/{rcaId}/submit-review

Get RCAs by Status¶

GET /rca/by-status?status=IN_PROGRESS&page=0&size=20

5 Whys Analysis¶

The 5 Whys methodology involves asking "why" iteratively to drill down to the root cause.

Add Why Question¶

POST /rca/{rcaId}/five-whys
Content-Type: application/json

{
  "question": "Why did the bearing fail?",
  "answer": "The bearing was running dry without lubrication",
  "evidence": "Oil analysis showed no lubricant present in sample"
}

Response:

{
  "data": {
    "id": 1,
    "rcaId": 10,
    "whyNumber": 1,
    "question": "Why did the bearing fail?",
    "answer": "The bearing was running dry without lubrication",
    "evidence": "Oil analysis showed no lubricant present in sample",
    "isRootCause": false,
    "isVerified": false
  }
}

Get 5 Whys Chain¶

GET /rca/{rcaId}/five-whys

Returns the complete chain of why questions for an RCA.

Response:

{
  "data": [
    {
      "id": 1,
      "whyNumber": 1,
      "question": "Why did the bearing fail?",
      "answer": "The bearing was running dry",
      "isRootCause": false
    },
    {
      "id": 2,
      "whyNumber": 2,
      "question": "Why was the bearing running dry?",
      "answer": "The automatic lubrication system was not working",
      "isRootCause": false
    },
    {
      "id": 3,
      "whyNumber": 3,
      "question": "Why was the lubrication system not working?",
      "answer": "The lubricant reservoir was empty",
      "isRootCause": false
    },
    {
      "id": 4,
      "whyNumber": 4,
      "question": "Why was the reservoir empty?",
      "answer": "There was no scheduled refill task",
      "isRootCause": true
    }
  ]
}

Mark as Root Cause¶

PATCH /rca/five-whys/{fiveWhyId}/root-cause?isRootCause=true

Required Role: ADMIN or MANAGER

Verify Why Answer¶

POST /rca/five-whys/{fiveWhyId}/verify

Required Role: ADMIN or MANAGER

Fishbone (Ishikawa) Analysis¶

The Fishbone diagram categorizes potential causes into standard categories.

Fishbone Categories¶

Add Fishbone Cause¶

POST /rca/{rcaId}/fishbone
Content-Type: application/json

{
  "category": "MACHINE",
  "causeDescription": "Lubrication system failure",
  "parentCauseId": null,
  "likelihoodScore": 4,
  "impactScore": 5
}

Parameters:

Get Fishbone Diagram¶

GET /rca/{rcaId}/fishbone

Returns causes grouped by category.

Response:

{
  "data": {
    "MACHINE": [
      {
        "id": 1,
        "category": "MACHINE",
        "causeDescription": "Lubrication system failure",
        "likelihoodScore": 4,
        "impactScore": 5,
        "riskScore": 20,
        "isRootCause": true
      }
    ],
    "METHOD": [
      {
        "id": 2,
        "category": "METHOD",
        "causeDescription": "No scheduled inspection",
        "likelihoodScore": 3,
        "impactScore": 4,
        "riskScore": 12,
        "isRootCause": false
      }
    ]
  }
}

Investigate Cause¶

Record investigation results for a fishbone cause.

POST /rca/fishbone/{causeId}/investigate
Content-Type: application/json

{
  "investigationResult": "Confirmed - lubrication pump failed due to seized impeller",
  "isRootCause": true
}

Get High-Risk Causes¶

GET /rca/{rcaId}/fishbone/high-risk?minScore=9

Returns causes with risk score (likelihood x impact) above the threshold.

CAPA Management¶

CAPA (Corrective and Preventive Actions) are linked to RCAs to address root causes.

CAPA Types¶

CAPA Statuses¶

Create CAPA¶

POST /rca/capa
Content-Type: application/json

{
  "title": "Implement Lubrication Schedule",
  "type": "PREVENTIVE",
  "actionPlan": "Create monthly lubrication inspection task",
  "dueDate": "2024-02-15",
  "assigneeId": 5,
  "priority": "HIGH"
}

Create CAPA from RCA¶

POST /rca/{rcaId}/capa
Content-Type: application/json

{
  "type": "CORRECTIVE",
  "title": "Replace Failed Lubrication Pump",
  "actionPlan": "Order and install new lubrication pump"
}

Update CAPA Status¶

PATCH /rca/capa/{capaId}/status?status=IN_PROGRESS

Verify CAPA Effectiveness¶

POST /rca/capa/{capaId}/verify
Content-Type: application/json

{
  "effectivenessRating": 4,
  "evidence": "No bearing failures in 3 months since implementation"
}

Parameters:

Get CAPAs by Status¶

GET /rca/capa/by-status?status=OPEN&page=0&size=20

Get Overdue CAPAs¶

GET /rca/capa/overdue

Get CAPAs Due Soon¶

GET /rca/capa/due-soon?days=7

CAPA Tasks¶

Add Task to CAPA¶

POST /rca/capa/{capaId}/tasks?assigneeId=8
Content-Type: application/json

{
  "title": "Order replacement pump",
  "description": "Contact supplier and place order",
  "dueDate": "2024-02-01"
}

Complete CAPA Task¶

POST /rca/capa/tasks/{taskId}/complete
Content-Type: application/json

{
  "completionNotes": "Pump ordered, delivery expected Feb 5"
}

Dashboards¶

RCA Dashboard¶

GET /rca/dashboard

Response:

{
  "data": {
    "totalRCAs": 45,
    "byStatus": {
      "DRAFT": 5,
      "IN_PROGRESS": 12,
      "REVIEW": 3,
      "APPROVED": 8,
      "CLOSED": 17
    },
    "byMethodology": {
      "FIVE_WHYS": 25,
      "FISHBONE": 15,
      "HYBRID": 5
    },
    "avgCompletionDays": 14.5,
    "rootCausesIdentified": 38
  }
}

CAPA Dashboard¶

GET /rca/capa/dashboard

Response:

{
  "data": {
    "totalCAPAs": 62,
    "byStatus": {
      "OPEN": 15,
      "IN_PROGRESS": 20,
      "PENDING_VERIFICATION": 8,
      "VERIFIED": 12,
      "CLOSED": 7
    },
    "byType": {
      "CORRECTIVE": 30,
      "PREVENTIVE": 25,
      "IMPROVEMENT": 7
    },
    "overdueCount": 5,
    "dueSoonCount": 12,
    "avgEffectivenessRating": 3.8
  }
}

Enums Reference¶

GET /rca/enums/methodologies
GET /rca/enums/fishbone-categories
GET /rca/enums/capa-types

Usage Examples¶

Complete 5 Whys Analysis¶

# Create RCA from failure
curl -X POST "http://localhost:1337/rca/from-failure/123?methodology=FIVE_WHYS" \
  -H "Authorization: Bearer $JWT"

# Add first why
curl -X POST http://localhost:1337/rca/1/five-whys \
  -H "Authorization: Bearer $JWT" \
  -H "Content-Type: application/json" \
  -d '{
    "question": "Why did the conveyor stop?",
    "answer": "Motor overheated and tripped",
    "evidence": "Thermal relay was triggered"
  }'

# Continue adding whys until root cause found
# ...

# Mark root cause
curl -X PATCH "http://localhost:1337/rca/five-whys/5/root-cause?isRootCause=true" \
  -H "Authorization: Bearer $JWT"

Fishbone Analysis¶

# Add causes to different categories
curl -X POST http://localhost:1337/rca/1/fishbone \
  -H "Authorization: Bearer $JWT" \
  -H "Content-Type: application/json" \
  -d '{
    "category": "MAN",
    "causeDescription": "Operator did not notice warning light",
    "likelihoodScore": 3,
    "impactScore": 4
  }'

# Get the complete diagram
curl -X GET http://localhost:1337/rca/1/fishbone \
  -H "Authorization: Bearer $JWT"

Creating CAPA Actions¶

# Create CAPA from RCA
curl -X POST http://localhost:1337/rca/1/capa \
  -H "Authorization: Bearer $JWT" \
  -H "Content-Type: application/json" \
  -d '{
    "type": "PREVENTIVE",
    "title": "Install high-temperature alarm",
    "actionPlan": "Install audible alarm connected to motor temperature sensor"
  }'

# Add tasks
curl -X POST "http://localhost:1337/rca/capa/1/tasks?assigneeId=5" \
  -H "Authorization: Bearer $JWT" \
  -H "Content-Type: application/json" \
  -d '{
    "title": "Procure temperature sensor",
    "dueDate": "2024-02-10"
  }'

Best Practices¶

1. Start with clear problem statements - Define the issue precisely
2. Gather evidence - Document findings at each step
3. Use appropriate methodology - 5 Whys for simple issues, Fishbone for complex
4. Score risks objectively - Use consistent criteria for likelihood/impact
5. Create actionable CAPAs - Specific, measurable, assigned, time-bound
6. Verify effectiveness - Follow up to confirm actions worked
7. Learn and share - Use dashboards to identify patterns