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    5 Why'sA

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    Mansoor Ali
    The document provides an overview and guidelines for using the 5 Whys technique to identify the underlying root cause of problems in manufacturing processes. It describes how to properly structure and ask the 5 Whys questions to get to the root cause, and provides an example of using 5 Whys to trace the root cause of crackers being crushed in some packaging to differences in moisture levels of wheat fields.

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    5 Why'sA

    Uploaded by

    Mansoor Ali
    32 views28 pages
    The document provides an overview and guidelines for using the 5 Whys technique to identify the underlying root cause of problems in manufacturing processes. It describes how to properly structure and ask the 5 Whys questions to get to the root cause, and provides an example of using 5 Whys to trace the root cause of crackers being crushed in some packaging to differences in moisture levels of wheat fields.

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    5 Why’sA

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    The document provides an overview and guidelines for using the 5 Whys technique to identify the underlying root cause of problems in manufacturing processes. It describes how to properly structure and ask the 5 Whys questions to get to the root cause, and provides an example of using 5 Whys to trace the root cause of crackers being crushed in some packaging to differences in moisture levels of wheat fields.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    32 views28 pages

    5 Why'sA

    Uploaded by

    Mansoor Ali
    The document provides an overview and guidelines for using the 5 Whys technique to identify the underlying root cause of problems in manufacturing processes. It describes how to properly structure and ask the 5 Whys questions to get to the root cause, and provides an example of using 5 Whys to trace the root cause of crackers being crushed in some packaging to differences in moisture levels of wheat fields.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 28

    5 Whys

    Overview

    Presented by: Javier Bustamante

    Objective:
    To provide guidelines on the purpose and methodology of 5 Whys technique used to identify underlying root cause(s) of problems related to the manufacturing process.

    Scope:
    All Engineering functions of Factory 1,2,3,4,HiRel & Warehouse responsible to coordinate internal and external complaints relative to their areas of responsibility.

    Course Effectiveness Assessment


    At the end of the training session, we will apply an exam that will cover the Most important aspects of the 5 Whys. This exam consists of 5 open Questions to be answered within 20 minutes. We will require at least 4 correct answers from the trainee to provide the training certificate.

    Course Effectiveness Assessment


    The Questions to be asked in the exam will come from the following: 1. What is 5 Whys? 2. What are the two basic questions to ask when starting a 5 Whys? 3. How many Whys are required in a 5 Whys exercise? 4. How should the whys be asked to maintain focus on the thought process?

    5. Which why is critical for the transition between the obvious and the not?
    6. What is the most common type of cause at the end of a well driven 5 Whys? 7. Name one method to assess coherence of thought process at the end of the 5 Whys. 8. What is the sought outcome of a 5 Whys analysis? 9. How can you demonstrate that the root cause of a problem has been found? 10. What is the risk of running into logical explanations in finding answers?

    Five Whys Example:


    Problem Description: A machine designed to wrap crackers in the individual stack bags was crushing the crackers in some bags, but not all.
    Why is the machine crushing crackers in some bags and not other bags? Answer from the Operator: Because some crackers are thicker than others. Why are some of the crackers thicker than others?

    Answer from the Baker: Some batches of flour contain more moisture than others.
    Why some batches of flour contain more moisture than others? Answer from the Farmer: Because some fields of wheat get more rain than others.

    Why do you allow some fields of wheat to get more rain than others?
    Answer from God: Because I am God!

    Five Whys Preparation


    Five whys is a Root Cause Analysis Tool. Not a problem solving technique. The outcome of a 5 Whys analysis is one or several root causes that ultimately identify the reason why a problem was originated.

    Problem

    Root Cause

    Corrective Actions

    Root Cause analysis Tools: Ishikawa Charts / Fish Bone /Cause & Effect Diagram Design of Experiments Is / Is not Analysis 5 Whys Statistical Data Analysis (Cpk, Paretto Charts, Anova,etc)

    Five Whys Preparation


    Any 5 Whys must address two different problems at the same time. (Why made?)

    Five Whys Preparation


    The second one must address the detection system that was not able to detect the defective part before it became a problem.

    (Why not detected?)

    Five Whys Preparation


    Even though the discipline is called 5 Whys is not always necessary to reach 5 before the root cause of a problem is fully explained; or it may take more than 5 whys to get to the bottom of it.

    Five Whys Preparation


    In any case, 5 has been determined, as a rule of thumb, as the number at which most root causes are clearly identified.

    For all the Five Whys:


    Ask the full question including the problem or cause behind it. If there is a problem with labeling ask: Why the parts were labeled incorrectly? If the answer is unreliable database ask: Why is the database unreliable?

    If we do not follow this approach answers to the whys tend to lose focus on the third or fourth why.

    Five Whys Preparation


    It is said that a well defined problem is a half resolved problem; hence it is important to state the problem as clearly as possible.

    Five Whys The First Why


    Clear statement of the reason for the defect or failure to occur, understood even by people that is not familiar with the operation where the problem took place.

    Five Whys The Second Why


    A more concise explanation to support the first statement. Get into the technical arena, the explanation can branch out to several different root causes here. It is OK to follow each of them continuing with their own set of remaining 3 whys and so forth.

    Five Whys The Third Why


    Do not jump to conclusions yet, follow the regular thought process even though some underlying root causes may start surfacing already.

    Five Whys The Third Why


    This 3rd why is critical for a successful transition between the obvious and the not so obvious. The first two whys have prepared you to focus on the area where the problem could have been originated; the last three whys will take you to a deeper comprehension of the problem.

    Five Whys The Fourth Why


    Clear your mind from preconceived explanations and start the fourth why with a candid approach. You may have two or more different avenues to explore now, explore them all.

    Five Whys The Fifth Why


    When you finally get to the fifth why, it is likely that you have found a systemic cause. Most of the problems in the process can be traced to them. Even a malfunctioning machine can sometimes be caused by an incorrectly followed Preventive Maintenance or Incorrect machine parameters setup.

    Five Whys The Fifth Why


    If you have reached the fifth why and you are still dealing with process related cause(s), you may still need one or two more whys to deep dive into the systemic cause.

    Five Whys Conclusion


    A good way to identify if the 5 Whys was done properly is to try to organize the collected data in one sentence and define it in an understandable manner.

    Five Whys Conclusion


    Something like: Problem Description occurred due to Fifth Why. This was caused by Fourth why mainly because Third Why was allowed by Second why, and this led to First Why.

    Five Whys Conclusion


    Do not forget that the sought outcome of a 5 Why exercise is a root cause of a the defined problem, not the resolution of the problem itself; that will come later. 5 Whys is not a standalone Problem Solving technique but more of a tool to aid in this process.

    Five Whys Conclusion


    Do not worry about Action plans and effectiveness verification yet as that will be addressed in the 8D; but focus more on identifying the reason that allowed the problem to happen and escape.

    Five Whys Conclusion


    One final point to ponder:

    A PROBLEM THAT CANNOT BE REPRODUCED IS A PROBLEM THAT HAS NOT BEEN RESOLVED YET.
    Challenge the root cause(s) that resulted from the 5 Whys exercise to try to reproduce the defect.

    Five Whys Exercise


    Problem Description: Washington monument is deteriorating
    Why is the Washington monument deteriorating? Chemicals being used to clean is too harsh?.
    Why is a harsh chemical being used to clean the Washington monument? Harsh chemicals must be used to remove heavy droppings from birds

    Why are there a lot of droppings from birds? There are a lot of birds.
    Why are there a lot of birds? There are a lot of spiders. Birds eat spiders. Why are there a lot of spiders? There are a lot of gnats. Spiders eat gnats Why are there a lot of gnats? They are atracted to light during dusk time.

    Five Whys Exercise


    Problem Description: Washington monument is deteriorating

    Solution: Turn on the lights half an hour later.

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