Why Why Analysis Training Material
Why Why Analysis Training Material
Why Why Analysis Training Material
A. B. C. D.
The 3x5 Why Project Background The 3x5 Why Method The 3 x 5Why Focus Templates
ST target is to share with our suppliers a common approach for problem solving methods especially for 3x5 Why why tool , to get complete, exhaustive FA report and to avoid any recurrence.
2. Improvement of 8D-Quality by Why-Why-RCA (Root Cause Analysis) In 2009, ST takes the next step and has started a project with our key suppliers. Focus on: * Implementing Why-Why-Analysis for non-conformance and non-detection aspects including system root causes * Getting a common understanding of a sustainable problem solving process * Having a comprehensive documentation of each failure which is understandable on a general technical knowledge level for our customers & management.
Hint: This project is part of the 8D improvement initiative which is measured acc. Toyota scoring methodology
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John Gowers <Confessio Amantis> dated approximately 1390 AD. The earliest known written version of the rhyme above (often taught to British children)
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Problem is defined as a gap between the way it should be and the way it is.
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If a problem is described wrongly, the result of problem solving will be also wrong. Example of wrong description
This is not a joke! Real example from a workshop with engineering colleagues
Customer give us feedback very late when a delivered sample was out of spec., and we can not make improvement timely.
Firefighting will result in reoccurrence 2. Master the key points of Naze-Naze to pursue real root causes Grasp every factor of the failure regularly, orderly
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5 x Why is a key step in the problem solving
Point of cause
Direct Cause
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5 Why investigation
Source: TMUK PPS
CAUSE INVESTIGATION
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Example
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Product: understand the function and construction with parts, drawings, etc Management: confirm the process and function with working process flow, rules, documents, etc Search in two dimensions of Produced and Delivered Non-conformance Non-detection
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Root Cause
Repeat asking why at least 5 times. However this does not mean to repeat asking meaninglessly why just 5 times, but to find the real root causes.
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Horizontal Deployment
C/M should be implemented not only in technical aspect, but also system aspect**.
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These 2 causes are to be found through thoroughly pre investigation. They are not necessarily part of 5Why.
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< Bad example > Dust level increased in clean room Machines are operated with full capacity Production volume is big
Demand increased
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Why
Mr.A did not pay attention
Why
Mr.A was careless
C/M
Be careful when walking
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The battery has not been replaced for long time and the pointer cannot be turned on.
Problem
The battery has run down The battery has run down The spring lost contact with the bulb
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Describe concretely
Operator did not know where the stop switch located Inexperienced operator was disposed at this process
X
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Bolt diameter is too big for the hole diameter The hole diameter is too small for the bolt diameter
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Is it a reoccurrence? Product B was mixed in product A After a measure was implemented Product C was mixed in product A
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Is 5 x Why logically done till system aspect? Are you convinced that the problem will not happen again? Is the report easy-to-understand from customers view? Can you present it to your customer?
Mindset of coach
The reason that students (my colleagues) are not learning is because the teacher (I) is not teaching.
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C. The 3 x 5Why-Focus
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The Method:
The problem-solver simply asks a Why-question approximately five times in series to analyze a certain aspect.
Because Why
Through the 3x5Why-method the root cause can be discovered 1. 2. 3. in the Manufacturing process to PREVENT failures (non-conformance) in the Quality test inspection process, in order to PROTECT the customer from test escapes (non-detection), and to identify/PREDICT weaknesses in the (Quality) Management or System, in order to exclude recurrence (-> learning organization towards zero defect).
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Definition System Root Cause: Organizational causes, that lead to a deviation. Example: Missing work flows, unclear descriptions and/or responsibilities not defined Solution or definition of measures is up to the management System Root Cause Recommendation: In the Fishbone-branch for methods organizational weaknesses can be considered.
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D. Templates
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2 x 5Why :
DD.MM.YYYY
C1 3 x 5Why : C2
DD.MM.YYYY
DD.MM.YYYY
WHY?
NON-DETECTION (PROTECT) ASPECT: Use this path to Investigate why the problem was not detected
WHY?
WHY?
WHY?
WHY?
WHY?
WHY?
WHY?
WHY?
C1
WHY?
WHY?
C2
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TECHNICAL ROOT-CAUSE
SYSTEM ROOT-CAUSE
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Why? Why? Why? Why? Why?
NON-DETECTION (PROTECT): Use this path to investigate why the prob lem was not detected
xce E
tem l
late p
Why?
Why?
Why?
Why?
Why?
Why?
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Naze-Naze / 3x5Why-Analysis Template Example: Weak Processability due to bad solderability (cont.)
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Naze-Naze / 3x5Why-Analysis
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