Lets just use a small example - an aspiring 6 sigma blackbelt was pointing out all the failures occurring at an inspection station - had to spend hours educating him that the root causes were occurring upstream and the results were being caught by the inspection system - it was his job to find the root causes, but the Pareto chart pointed at the inspection system. Eventually got him pointed in the right direction....
Where to even go with everything you stated...
Lets just use a small example - an aspiring 6 sigma blackbelt was pointing out all the failures occurring at an inspection station - had to spend hours educating him that the root causes were occurring upstream and the results were being caught by the inspection system - it was his job to find the root causes, but the Pareto chart pointed at the inspection system. Eventually got him pointed in the right direction....
Been there, Done That!!!!!