Once we have identified the losses, it is important to answer the question: Why are these losses occurring?

The best way to analyze the causes is through a brainstorm session, which is a meeting with the Team and other staff from the focus areas to discuss the losses. One person can act as facilitator and make notes on a whiteboard so that everyone can follow the discussion.

It is important to continue asking “why” until you have found the real cause or “root cause” of the problem. A common problem with boilers is un-burnt ashes. Why? Because the air supply to the boiler is too low. Why? Because the meter gives a wrong reading of air supplied. Why? Because the meter has not been maintained properly. Why? Because boiler operators nor maintenance staff maintain the boiler. Why? Because the maintenance procedures do not specify who should maintain the boiler and how often. This is the root cause of your loss. And only now it is possible to come up with options to solve this problem permanently. In our example, increasing the air supply is a temporary solution (saving little energy in the short term), whereas changing maintenance procedures is a permanent solution (saving a lot of energy in the long term).

Worksheet 15, the Fishbone Diagram tool, and Company examples from companies that participated in the GERIAP project can help you find the causes for losses at your selected focus areas.

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