4. Root Cause Analysis

Root cause analysis is primarily a reactive method, focussing on the detection of harmful defects in finished food products. As such it has a definite disadvantage compared to proactive methods, like HACCP, which will be discussed in the next chapter. If a contamination in the product is only detected post-processing, the company may face a costly recall, a negative sales impact on the product and/or entire brand, or even legal and ethical liabilities. However, a root cause analysis is an excellent tool to investigate and iradicate identified or potential food safety and quality issues.

Step 1: Identify potential issues e.g. by analyzing customer complaints, conducting internal audits, or reviewing safety and quality records.

Step 2: Determine the root cause of the issue by conducting further research to identify the underlying causes. The method used is called the '5 whys?', which means that the issue is challenged by asking 'why?' five times, and thereby constantly digging deeper through the chain of causalities (triggers, actions, decisons made, etc.) that eventually lead to the issue.

Step 3: Take corrective action to prevent similar issues from happening again. This may involve making changes to processes and procedures, training staff, changing equipment or materials, or other corrective measures.

Step 4: Monitor the effectiveness of the corrective action and document all changes made.

Example: A customer complaint was received about a product that had an off-taste. Through the first 'why?', it was determined that the the off-taste was caused by a certain ingredient that had gone off. The second 'why?' determined that the ingredient had gone off becuase it had been stored in an area with high temperatures. The third 'why?' showed that staff members used the inadequate storage instead of the designated storage area. The fourth 'why?' lead to the insight that the designated storage area was inconveniently located. The last 'why?' lead to the understanding that the floor layout did not suit the workflow. As a result the access ways to the storage area were re-designed to ensure easier access. Staff members were informed and received a refresher training on storage conditions.