Operational ExcellenceOE-005

Why the same error returns after you fixed it

4 min readIntermediate18 August 2026
repeat errorsroot causepsychological safetyreportingcontinual improvement

The question worth asking

Put this to a group of department heads and watch the room: why do the same mistakes keep occurring, even after they have been fixed?

The usual answer is culture. That may feel true, but it is rarely the mechanism, and it is almost never deliberate.

Where it actually fails

The people doing the work already know every problem that occurs in their working day. Most of them correct those problems immediately — that is what competent operators do.

What does not happen consistently is everything after the correction. The workflow should run:

Problem occurs → problem solved → problem reported → investigated → recorded → cause identified → permanent solution applied.

In practice it stops at the second step. The work carries on. Nothing is recorded, so nothing is analysed, so the cause survives, so the problem returns to somebody else next month.

Two barriers, both structural

The first is friction. If reporting is clunky, slow or unclear, teams will not use it. That is not laziness — the time spent reporting is not worth it in the moment, even though it is decisive over a year.

The second is response. One exchange settles the question for good:

"I told the supervisor and they said, what can I do about it? How am I supposed to work with that?"

Once that has happened, the reporting rate for that team is set, and no system will raise it.

The smallest intervention that works

A whiteboard. Two columns: The Problem and The Reason.

  • Summarise each problem in as few words as possible. Think hard about the real reason, and write it in the second column.
  • Sixty seconds per entry, every time something occurs.
  • Review the entries at the start of each shift, as a group.
  • Discuss problems as actions, never people as blame.

Within weeks something specific happens: someone writes a problem, looks up, and finds their reason is already on the board. That means either the earlier fix did not go deep enough, or it did and nobody told them.

Both are findings. Neither was previously visible.

Expect the count to rise

Recorded problems increase first, because trust is increasing. They fall sharply afterwards, as repeated causes are removed for good.

A leadership team that treats the initial rise as a deterioration will suppress the thing it asked for. That single misreading closes more reporting systems than poor design ever has.

A note on individuals

Occasionally a person is genuinely the cause. Before acting, four questions are owed: were they recruited into the right role, are they struggling personally, were they properly briefed, and what is the state of their relationship with their manager?

Accountability without empathy is not culture. It is control, and it produces silence.

OE-005 · v1 · Published 18 August 2026