At an industrial food processing facility, maintenance headaches had become the new normal. Conveyor belts stopped without warning, cooling units tripped overnight, and technicians scrambled between emergencies with no clear record of past fixes. Each breakdown meant lost production time — and lost sleep for the maintenance manager.
One morning, after yet another unplanned shutdown, the plant manager gathered her team. She drew a fishbone on the whiteboard and said, “We can’t just keep reacting. Let’s figure out why this keeps happening.”
They listed every possible cause — inconsistent inspections, missing parts data, unclear task logs, and reactive scheduling. The Fishbone Analysis revealed the real issue wasn’t just the machines; it was the lack of a centralized maintenance system to track, analyze, and prevent failures.
That realization changed everything. The team didn’t just fix equipment; they fixed the process — and that started with implementing a smarter, connected maintenance approach.
Featured image for MaintBoard’s guide on Fishbone Analysis and effective root cause problem-solving.
Introduction to Fishbone Analysis
Fishbone Analysis, also known as the Ishikawa Diagram or Cause and Effect Diagram, is a structured root cause analysis tool used to visualize, categorize, and address complex problems. It’s widely applied in Six Sigma, quality management, and project management to find what’s really causing an issue rather than addressing only symptoms.
Organizations use fishbone diagrams for RCA (Root Cause Analysis) to trace problems across multiple dimensions such as manpower, machinery, methods, materials, and environment. With editable fishbone diagram templates available in Excel, Word, and online software, teams can now perform cause and effect analysis faster and more accurately.
What Is a Fishbone Diagram and Why Use It?
A fishbone diagram (or root cause diagram) visually maps out all potential causes contributing to a specific problem. The diagram’s structure resembles a fish skeleton — the “head” shows the problem statement, and the “bones” represent potential cause categories.
This fishbone analysis tool helps teams:
- Organize brainstorming efforts
- Identify multiple potential causes
- Encourage cross-functional discussion
- Create actionable insights for root cause analysis (RCA)
It’s a cornerstone among cause and effect analysis tools, often paired with the 5 Whys method for deeper cause validation.
The Origin of the Fishbone Diagram
Developed by Kaoru Ishikawa in the 1960s, the Ishikawa Fishbone Diagram emerged from Japan’s quality revolution. Initially used in industrial engineering, it became central to Total Quality Management (TQM) and Six Sigma practices. Ishikawa’s approach to cause and effect analysis made it easier to visualize systemic failures across organizations.
Today, it’s adopted globally for RCA fishbone diagrams in healthcare, IT, manufacturing, and education — including the NHS Fishbone Analysis model used in medical root cause investigations.
How the Fishbone Diagram Works
A fishbone diagram for root cause analysis starts with a clearly defined problem statement (the “effect”). From there, categories branch out, representing potential sources of variation or failure. Common root cause categories include:
A Fishbone (Ishikawa) diagram visualizing root causes using the 6M method for effective problem-solving.
- People (Manpower)
- Machines (Equipment)
- Methods (Processes)
- Materials (Inputs)
- Measurement (Data Quality)
- Mother Nature (Environment)
This classification, known as the 6M Method for Root Cause Analysis, helps teams structure their cause and effect analysis efficiently.
👉 Example: In a fishbone diagram for quality improvement, a manufacturer might explore “Defective Product” as the head and branch out into 6M categories to find the root causes.
Step-by-Step Process of Fishbone Analysis
-
Define the Problem
Write a precise problem statement, such as “Customer complaints increased by 25% in Q4.” This becomes the “head” of your fishbone.
-
Identify Major Cause Categories
Select relevant categories using the 6M fishbone diagram or 8P model (for marketing and services).
-
Brainstorm Potential Causes
Gather a diverse team to brainstorm causes under each main category. Use fishbone diagram templates or an online RCA fishbone tool to map results.
-
Drill Down Using the 5 Whys
Combine the Fishbone and 5 Whys method. For each cause identified, ask “Why did this happen?” five times to uncover deeper systemic issues.
-
Prioritize and Implement Solutions
After analysis, identify critical causes and develop corrective action plans. Use Fishbone Root Cause Analysis Templates (Excel or Word) to track actions and assign ownership.
6M Method in Detail (Cause and Effect Root Cause Analysis)
The 6M Root Cause Analysis method is foundational to fishbone problem-solving.
CategoryDescriptionExample CauseMan (People)Human errors, skill gapsInsufficient trainingMachineEquipment or software issuesOutdated hardwareMethodProcedures or workflow inefficienciesLack of standardizationMaterialRaw materials or inputsLow-quality suppliersMeasurementInaccurate dataFaulty instrumentsMother NatureEnvironmental factorsPoor lighting or temperature
This framework ensures all possible cause dimensions are explored — improving the reliability of your root cause and effect analysis.
Common Fishbone Diagram Templates and Tools
To perform Fishbone Root Cause Analysis, professionals often use customizable templates.Here are some popular options:
- Root Cause Fishbone Diagram Template (Excel) – Ideal for quality control tracking
- Fishbone Diagram Editable Template (Word or PowerPoint) – Great for team collaboration
- Online Fishbone Diagram Software – Tools like Miro, Lucidchart, and Canva offer root cause analysis diagram templates for quick visualization
- Fishbone Diagram for RCA (Root Cause Analysis) – Combines both Ishikawa analysis and 5 Whys for deeper insights
💡 Tip: You can find RCA Fishbone Diagram Templates on ASQ.org or within project management software like ClickUp or SmartDraw.
Examples of Fishbone Analysis in Action
Example 1: Fishbone Diagram in Manufacturing
A fishbone analysis example in manufacturing might target “High Defect Rate.”Using the 6M Fishbone Diagram, the team identifies causes like:
- Insufficient operator training (Man)
- Poor maintenance schedule (Machine)
- Inconsistent process flow (Method)After applying corrective actions, defect rates drop by 40%.
Example 2: Fishbone Diagram in Healthcare
The NHS Fishbone Analysis model helps identify patient safety issues such as “Medication errors.”Causes may include miscommunication (People), unclear labeling (Material), and system glitches (Machine).
Example 3: Fishbone Diagram in Project Management
Project delays are analyzed using Fishbone Analysis for Project Management to uncover scheduling, resource, or communication bottlenecks.
Difference Between Fishbone and 5 Whys Analysis
While both are root cause analysis tools, they serve complementary roles:
MethodPurposeBest ForFishbone DiagramVisualizes multiple potential causesComplex or team-based analysis5 WhysDigs deep into one causal chainSimple or individual RCA
Most modern teams use the Fishbone and 5 Whys together for a holistic root cause effect analysis.
Advantages of Using Fishbone Analysis
- Promotes systematic problem-solving
- Encourages collaboration and brainstorming
- Enhances understanding of process interdependencies
- Visual representation supports effective decision-making
- Works well with other root cause analysis tools like FMEA and Pareto Charts
However, remember that fishbone analysis depends on accurate data and team input; otherwise, conclusions may be biased.
Fishbone Analysis in Modern Workflows
Today, digital tools make fishbone analysis faster and more accessible. You can build diagrams directly in Excel, Minitab, or online RCA tools.
- Fishbone Diagram Online Tools: Lucidchart, Canva, Creately, and Miro
- Fishbone Analysis Excel Templates: Ideal for structured RCA documentation
- Fishbone Analysis Software: Used in manufacturing, healthcare, and education for continuous improvement
These help standardize root cause analysis fishbone templates and ensure consistent team practices.
Frequently Asked Questions (FAQs)
Conclusion: Solve Root Causes Faster With MaintBoard’s Built-In RCA Tools
Fishbone Analysis is powerful — but creating diagrams manually, tracking causes across teams, and documenting RCA outcomes can still slow maintenance teams down.
MaintBoard removes all that friction.
With our CMMS, you can:
- Create digital Fishbone / Ishikawa diagrams directly inside the system
- Attach evidence, images, and notes to each cause
- Track recurring failures across assets
- Automate corrective actions and follow-up tasks
- Build a complete RCA trail for audits and compliance
If your goal is faster, data-driven root cause elimination, MaintBoard gives you everything in one place — without spreadsheets, PDFs, or scattered documents.