5 Whys Training Oct 12 2011

8/13/2019 5 Whys Training Oct 12 2011

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Operational Excellence = Safety Quality Productivity Continuous Improvement Customer Satisfaction

12 OCTOBER 2011

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Problem Root Cause

Corrective

Actions

Root Cause analysis Tools:

Ishikawa Charts (Fish Bone) 5 Wh s

Cause & Effect Diagram.

Statistical Data Analysis (Cpk, Pareto

Charts,etc)

The 5 Whys?is an analysis tool to support root

cause anal sis.

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5 Wh s

The desired outcome of a 5 Why exercise is

A root cause of a the defined problem, not theresolution of the roblem itself!

5 Whys is not a stand alone Problem Solving technique.It is a tool to aid in this process.

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Pre arin for 5 Wh s

Go to the source, data

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Trainin ExerciseSituation: There is oil in an aisle way of the factory.

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5 Wh s Problem StatementA well defined problem statement is critical to finding the

It is very important to state the problem as clearly as possible.

Define the problem in terms of the requirements that are not

being met.

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Com lete the Problem Statementfor this exercise:

way which could present a safety and fire

hazard.

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st

Complete a clear statement of the reason for thee ec or a ure o occur

Must be able to be understood even by people that are notam ar w e opera on w ere e pro em occurre .

Use a short, concise sentence that explains thereason.

It is Okay to write it down even if it seems too obvious foryou. (It may not seem that obvious to other persons that willread the document).

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.

Com lete the 1st. Wh & its Cause:

Why is there oil in the aisle way?

Cause: The machine is leaking.

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nd .

omp e e a conc se exp ana on n e orm o e . y

statement to support understanding the cause in the 1st. Why?.

Get into the technical detail

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.

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Tr inin Ex r i 2nd

. Wh ?

Com lete the 2nd. Wh ?& its Cause:

Why is the machine leaking?

Cause: A seal is damaged.

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5 Whys 3rd. Why?

Do not jump to conclusions yet

o ow e regu ar oug process even oug some

underlying root causes may start surfacing already.

between the obvious and the not so obvious.

where the problem could have been originated; the lastthree whys wil l take you to a deeper comprehension of theproblem. Visualize the process where the product went

likely sources for the problem to occur.

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Tr inin Ex r i r . Wh ?

Com lete the 3rd. Wh ?& its Cause:

Why is the seal damaged?

Cause: There are metal shavings in the machine

coolant which damaged the seal.

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5 Wh s Theth

. Wh ?

Clear your mind from preconceivedexp ana ons an s ar e our w y w acandid approach.

May have two or more different avenues toexplore now, explore them all. Even if one orseveral of them turn out not to be the root causeof the problem, they may lead to continuousimprovements.

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th

Com lete the 4th. Wh ?& its Cause:

Why are there metal shavings in the coolant?

Cause: The screen on the coolant pump has

been damaged.

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5 Wh s 5th

. Wh ? At the 5th. Why?, it is l ikely that you have found a

.

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.

.with process related cause(s), you may still need one or two more

whys to deep dive into the systemic cause.

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Tr inin Ex r i th

. Wh ?

Com lete the 5th. Wh ?& its Cause:

Wh is the screen on the coolant umdamaged?

Cause: The screen on the coolant pump islocated where parts being machined hit and

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5 Wh s Conclusion Test to identify if the 5 Whys was done properly:

statements that define the situation in an understandablemanner.

If statements ar fragmented or meaningless, chances are that .

revisit the 5 Why sequence and identify those gaps to fill themin.

A coherence in the way that the statements are assembledshows consistenc on the thou ht rocess.

Something like:

Problem Description occurred due to Fifth Why.

Therefore, this was caused by Fourth Why. Therefore,because Third Why was allowed by Second Why.

Therefore, this led to First Why.

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Training Exercise Conclusion?

Test the Conclusion by constructing a chronological

series of therefore statements backwards:

and damaging it.

Therefore, the damaged screen is allowing metal. Therefore, the metal shavings in the coolantare damaging a seal.

,oil to leak from the machine. Therefore, this lead to oil leaking into

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conclusion type testing after each Why?/Causeis identified!

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,

effectiveness verification during the 5 Why Exercise.

Focus more on identifying the reason that allowed the

problem to happen and escape.

If ou can come u with a reasonable answer the exercise

would be successful.

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Coolant on floor at base of machine

Machine leaking

A seal was dama ed

Metal shavings in coolant

Screen on coolant pump was broke

Screen is located where parts hit and

damage it

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Documents

5 Whys Training Oct 12 2011