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The 5 Whys: An Introduction January 21, 2014

The 5 Whys: An Introduction January 21, 2014. Motivation. When something goes wrong, we tend to see it as a crisis and seek to blame. The majority of the corrective action responses we receive from our suppliers stop their problem analysis at the operator or inspector level.

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The 5 Whys: An Introduction January 21, 2014

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  1. The 5 Whys: An IntroductionJanuary 21, 2014

  2. Motivation • When something goes wrong, we tend to see it as a crisis and seek to blame. • The majority of the corrective action responses we receive from our suppliers stop their problem analysis at the operator or inspector level. • A better way is to see it as an opportunity to learn about our system and processes, and how to make it harder for someone to make a mistake. • Today we will learn the technique of asking “Why” five times to discover why the process failed.

  3. Introduction to the 5 Why Method Overview The 5 Whys is a method to explore cause and effect relationships. We peel away the symptoms to identify root causes. • Engage employees directly involved with the problem • Analyze the process to discover weaknesses that: • Cause the defect • Waste our time • Hurt our company’s reputation • Eat our profits

  4. Introduction to the 5 Why Method Overview • Assume any problem is preventable and worth preventing • Problems are caused by weak or poorly defined processes more than individual incompetence • Commit to making an investment in the corrective action(s) needed to eliminate the defect • INTENT - Make it harder for someone to make a mistake Boom Start Finish

  5. Five Whys Preparation Five Whysis one of many Root Cause Analysis Tools Problem Root Causes Corrective Actions • Root Cause analysis Tool Examples: • 5 Whys • Cause Map • Not Recommended: • Cause & Effect Diagram (Fishbone)

  6. Five Why – A Simple Example Ask “Why?” about 5 times and you will likely discover a systemic cause for the problem. Problem- Flat Tire • Why? There is a tack in the tire • Why? Car ran over tacks • Why? Tacks on garage floor • Why? Box of tacks on shelf split open • Why? Box is wet • Why? Rain entered hole in roof • Why? A roof shingle is missing • Why? Wind storm blew shingle off Condition Action Condition Action Condition Action Condition Action

  7. Five Whys Preparation • Marvin Engineering uses a 2-legged 5 Whyto addresses different systemic issues. • How was the problem created? • Why was the problem not detected? • Failing to detect the nonconformity allowed it to escape to the customer.

  8. Five WhysLeg One My car will not start Recharge the battery The battery is dead The alternator is not working Replace the belt The alternator belt broke The belt was old and beyond its useful service life Follow manufacturer recommendations Car was not maintained according to recommendations

  9. Five WhysLeg Two The quality system did not detect the defect Leg 2 is needed only when there is an escape. An escape is a defect that gets passed on undetected to the next work center and/or to the customer.

  10. Check Your Logic My car will not start Why? The battery is dead Why? The alternator is not working Why? The alternator belt broke Why? The belt was old and beyond its useful service life Car was not maintained according to recommendations Why?

  11. Check Your Logic Begin with the last Why. Read it, say the word “therefore,” and continue backward to the first Why. My car will not start Therefore The battery is dead Therefore The alternator is not working Therefore The alternator belt broke Therefore The belt was beyond its useful service life Therefore My car was not maintained according to recommendations

  12. Deeper Whys Yield Better Solutions Example: Jefferson Memorial Problem: The Jefferson Memorial is deteriorating Why? Too much washing Why? Excess bird droppings Why? Lots of spiders to eat Why? Lots of bugs to eat Why? Lights are switched on before dusk

  13. Deeper Whys Yield Better Solutions Problem Statement: Jefferson Memorial is Deteriorating Too much washing Why? Too much washing was why the Memorial was deteriorating Why? Excess bird droppings Lots of spiders to eat Why? Bug Spray – Would eliminate the bugs, but introduces new problems (e.g. health concerns). Lots of bugs to eat Why? Turn lights on ½ hour later – a less costly solution without side affects. Lights are switched on before dusk Why?

  14. Introduction to the 5 Why Method Questions?

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