Root Cause Analysis and Sherlock Holmes: A Detective Approach to Technical Problem Solving

In the fast-paced world of high-tech and healthcare innovation, every detail matters. A tiny deviation can lead to malfunctioning products, unreliable processes, and dissatisfied customers. When problems persist despite repeated attempts to fix them, it's time to stop working harder and start thinking smarter. It's time to channel our inner Sherlock Holmes. 

At Holland Innovative, we believe that true problem-solving requires deep observation, analysis, and logical deduction—exactly the skills that made Holmes a legend. Root Cause Analysis (RCA), especially when paired with Statistical Engineering, provides the structure and depth to uncover the true root causes of technical challenges—and resolve them permanently. 

From Symptoms to Root Causes: What RCA Is All About 

RCA is a structured approach to identify the fundamental cause of a problem. It doesn’t stop at fixing symptoms—it digs deeper to answer: “Why did this happen?” Only by addressing the real cause can we implement lasting solutions and prevent the issue from resurfacing. 

A simple definition of RCA is: 
“The process of identifying the underlying cause of a deviation or failure, so that appropriate corrective actions can be taken to prevent recurrence.” 

But in reality, problems are rarely simple. Like a complicated crime scene, the clues may be messy, the data noisy, and the true cause well hidden among many suspects. 

What Would Sherlock Do? 

Imagine a recurring production failure. The root cause isn’t obvious. Brainstorming sessions have been held. Hypotheses tested. Parts replaced. Still, the issue returns. 

What would Sherlock Holmes do? 

1. Observe without bias. He would study the scene meticulously and look for patterns.
2. Gather only reliable data. Holmes wouldn’t rely on hearsay or incomplete records.
3. Eliminate alternatives. Through logical deduction, he’d narrow the field until only one cause remained.
4. Value facts over opinions. No guessing—only evidence.
5. Use comparisons. What differentiates a working system from a failing one?

These principles align remarkably well with Holland Innovative’s RCA method using Statistical Engineering. 

The RCA Breakdown Structure: A Systematic Path to the Truth 

Our structured process is called the Problem Solving Breakdown Structure (PSBS). It guides teams through RCA step by step: 

1. Problem Selection
   • Define the issue clearly and unambiguously.
   • Avoid distractions or scope creep.

2. Project Breakdown
   
   • Zoom in on critical areas of the problem
   • Tackle focused challenges, not the entire system at once.

3. Problem Solving Breakdown 
   • Identify the major root cause
   • Use statistical tools to find where the most variation is introduced.

4. Breakdown 
   • Eliminate or control MjRC
   • Validate the fix and confirm the problem won’t reoccur.

This structured detective work ensures that each step builds logically on the previous one—leading to lasting results. 

Statistical Engineering: The Scientific Detective's Toolkit 

Statistical Engineering (SE) merges statistical tools with engineering expertise. It begins with one core belief: almost every problem has one main root cause contributing most significantly to the variation. Finding and understanding this Major Root Cause (MjRC) is key. 

SE enables us to: 

• Analyze measurement systems. Is your data trustworthy?
• Apply strategic tools. Strategy diagrams, decision trees, and problem breakdowns guide our analysis.
• Use advanced methods. Techniques like part swap analysis, GP/TP comparison, and multi-vari charts help isolate variables.
• Focus on what matters. SE identifies the critical factors that have the greatest impact on product performance.
  
  

“Listening to the Parts”: Learning from the Physical Evidence 

A core element in our approach is “Listening to the Parts.” That means we don’t just study numbers—we examine the physical products themselves. 

• Compare the worst and best parts (Terrible Parts vs. Great Parts).
• Disassemble and reassemble. If the problem persists, it may stem from a component. If it disappears, focus shifts to the assembly process. 
• Focus on extremes. Differences often become clearest at the boundaries.

This hands-on, investigative approach keeps the analysis grounded in the real world—just like Holmes inspecting a crime scene. 

Training: Turning RCA Into a Core Competence 

At Holland Innovative, we don’t just apply RCA—we teach it. We’ve applied this strategy successfully time and again—especially when teams feel stuck and no longer see a clear path forward. Because we believe root cause thinking is a core competence for engineers, managers, and teams in innovation-driven organizations. 

1. One-Day RCA Workshop

A powerful, fast-paced introduction to RCA and SE for senior engineers and executives. You'll learn: 

• The breakdown structure of Statistical Engineering 
• Practical tools like strategy diagrams and part swap analysis
• How to assess measurement systems 
• Real-world case examples and exercises

2. Five-Day RCA Training Program

For those who want to master RCA. In five focused modules, participants learn to: 

• Understand variation and process behavior 
• Apply advanced tools like multi-vari and Design of Experiments (DoE)
• Build structured analyses and management reports
• Solve problems based on their own real cases

These trainings create skilled problem solvers who think critically, act decisively, and deliver measurable impact

Why RCA Matters in High-Tech and Healthcare 

In industries like semiconductors, medtech, and complex manufacturing, even small deviations can have massive consequences. Think of: 

• Micron-scale tolerances in chip fabrication
• Medical devices where reliability can save lives
• Automated lines where downtime costs millions

In these contexts, ad-hoc problem solving isn’t good enough. You need a robust, structured approach you can trust—one that delivers results consistently. That’s why RCA, done right, is essential—not optional. 

A Culture of Curiosity and Persistence 

RCA teaches us to dig deeper. As Sherlock Holmes once said: 
“There is nothing more deceptive than an obvious fact.” 

That’s why we encourage a culture where teams ask: 

• What’s really different about the failing product?
• Are we missing key data?
• What do these symptoms actually tell us about the system?

This mindset of structured curiosity leads to insight—and insight leads to innovation. 

Beyond Fixing: Building a Culture of Continuous Improvement 

RCA is more than a tool to solve today’s problems. It’s a way of thinking. A method of learning. A discipline of continuous improvement. 

Organizations that embrace RCA: 

• Identify issues faster 
• Collaborate more effectively 
• Solve problems at the root 
• Improve reliability and customer satisfaction 

That’s the foundation of sustainable innovation. 

Becoming the Detective Your Organization Needs 

Every organization faces problems. But how you solve them defines who you are. 

RCA through a Sherlock Holmes lens means: 

• Patience and precision 
• Attention to detail and system thinking
• Fact-based reasoning 
• Structured steps—not reactionary chaos 

At Holland Innovative, we support you—through coaching, training, and project support—so you can become the kind of problem solver your team needs. For your products, your processes, and your customers. 

RCA as Part of a Certified Reliability Career Path

Root Cause Analysis isn’t just a powerful tool—it’s a teachable skill. At Holland Innovative, RCA is a core component of the internationally recognized Reliability Foundation Certification Program. Through the dedicated training module RF10 – RCA, engineers learn to apply RCA methods in a structured, data-driven way.

Whether you're pursuing a Green Belt, Black Belt, or CRE certification, RCA plays a central role in building your capability to identify and eliminate the true causes of failure. It's not only about solving today's problem—it's about equipping professionals to prevent tomorrow’s.

Explore the full Reliability Certification framework here:
Becoming a Certified Reliability Expert.

Ready to investigate your biggest challenges? Let’s solve them—together.