5 Why’s for Root Cause Analysis

Objective

Understand the 5 Why’s Method for problem solving.

Apply the 5 Why’s Method to identify root cause.

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The 5 Why’s

The 5 Why’s approach to root cause analysis is described as asking the question “why” five times.This technique is attributed to a Japanese method of determining the root cause.The 5 Why’s method can be used to determine the root cause for ANY problem.

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Advantages of 5 Why’s

Simple - It’s easy to use.Effective – separates symptoms from the cause.Flexible – works well alone, but can be used with other CI Tools.Engaging – creates TEAMWORK!Inexpensive – just the cost of your brain power!

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CI Tool Overview

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Opportunity

Brainstorming

5 Whys

Fishbone

PDCA

Template

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Example Problem

COLO Event at SAB.

Over-baked product: Classic Chip Galores Cookies.

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Why’s

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Why are the cookies over baked?

Why is there less volume?

Why did we reduce the cuts per min?

Why was the oven slowed down?

Why are there doubles?

Why are the wires loose?

Why is the clamp loose?

Why is the bolt stripped?

Less volume in the oven

We reduced the cuts per minute

The oven was slowed down

We were seeing a lot of doubles

The cutting wires are loose

The clamp holding the wires is loose

The bolt that tightens the clamp is stripped

It was over tightened and the PM has not been completed to replace the bolt

Solution

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The PM was missed therefore the bolt has not been replaced.

Add the bolt to the CI&L Matrix for the line so that if a defect occurs, the bolt is replaced.

Example – Jeffersonian Memorial

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Problem: The stone of the memorial was decaying.

Why’s

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Why the decay? The building is frequently washed

Why does the building have to be washed so often?

To remove all the bird droppings from the abundance of birds around the monument

Why are there so many birds? There are 1000’s of spiders there for the birds to eat.

Why are there so many spiders? There are 1000’s and 1000’s of midges there for the spiders to eat.

Why are there so many midges?The midges are attracted to the spotlights that have come on and it creates a mating frenzy every evening.

Solution

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The National Parks turn on the spotlights that illuminate the building every evening at dusk and millions of these midges emerge in a mating frenzy. The excited midges are attracted to the light.

The Parks service has delayed the turning on of the spotlights to one hour after sunset

The Result

The midge population is down 90%

The food chain has been broken

There are now less frequent washings

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Group Exercise for 5 Why’s

What problem is your team facing?COLO, shrink, downtime, overtime, missed PPPH, etc.

Apply the 5 Why’s Method to find the root cause.

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Questions?

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