5 why training slides oct 14, 2009
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Sky Miltronics/Trust TechnologiesAugust 2009
5 WHY TRAINING
Introduction to Systematic
Problem Solving
Sky Miltronics/Trust TechnologiesAugust 2009
Code of Conduct Arrive to Training on Time and Keep to Time
Schedule
Listen to Everyone's Opinion with Respect
Keep an Open Mind
Respect and Support Team Roles
Stay in the Meeting while Others are Talking
Turn Off Mobile Phones (Put on Silent as a Minimum)
Have Fun!
Sky Miltronics/Trust TechnologiesAugust 2009
INSTRUCTOR: John F. Petak7:00 am - 7:30 am Introductions / Review the Current Situation
7:30 am - 8:00 am Introduction to TOPS 8D
8 :00 am - 8:20 am Individual Exercise - “ Puzzle ”
8:20 am - 8:50 am Defining Problems
8:50 am - 9:00 am Break
9:00 am - 9:30 am Introduction to 5 Why’s
9:30 am - 10:10 am Team Exercise – “ Albatross ”
10:10 am - 10:50 am Team Exercise – “The Real World”
10:50 am - 11:00 am Wrap Up / Feedback
Agenda
Sky Miltronics/Trust TechnologiesAugust 2009
Father of Just In Time ManufacturingDo you know his name?
Sky Miltronics/Trust TechnologiesAugust 2009
“If you don’t ask the right questions, you don’t get the right answers. A question asked in the right way often
points to its own answer. Asking questions is the ABC of diagnosis. Only the inquiring mind solves problems. “
Why?
6
Sky Miltronics/Trust TechnologiesAugust 2009 7
The PUZZLE Exercise
Sky Miltronics/Trust TechnologiesAugust 2009
According to WEBSTERS Dictionary:
A Problem is a difficult or perplexing question or issue; a question posed for consideration, discussion or solution.
In Lean Manufacturing:
A Problem is a gap between the current condition (what is) and the desired condition (what should be) and the CAUSE for the gap is unknown.
8
What is a Problem?
Sky Miltronics/Trust TechnologiesAugust 2009
According to WEBSTERS Dictionary:
A Cause is a reason for an action or condition; something that brings about an effect or result
In Lean Manufacturing:
A Cause is a factor that immediately precedes the problem and always produces it. For a factor to be a Cause, it must also be capable of producing the problem by itself
9
What is a Cause?
Sky Miltronics/Trust TechnologiesAugust 2009
• By repeatedly asking the question “Why?”, you can peel away the layers of symptoms and identify the Root Cause of the problem.
• A Root Cause is an Identified Reason or Source for the presence of a Defect or Problem
• Once a Root Cause is identified and corrected, prevention of the recurrence is possible.
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Why 5 Whys?
Why?
Why?
Why?
Why?
Why?
Root Cause
Sky Miltronics/Trust TechnologiesAugust 2009
• Points to the Root Cause of the Problem
• Highlights the relationship between several potential Root Causes of a Problem
• Allows for rapid problems solving without the use of Statistical Tools
zzZZ?zzZZ?zzZZ?zzZZ?zzZZ?
WHY?WHY?WHY?WHY?WHY?
WHY?WHY?WHY?WHY?WHY?
WHY?WHY?WHY?WHY?WHY?
11
Benefit of 5 Whys
Sky Miltronics/Trust TechnologiesAugust 2009
1. Write Down the Specific Problem- Helps you define it completely- Focuses the team on the same problem
2. Ask WHY the Problem happened and write down the Answer
3. If the Answer is not the Root Cause, Ask WHY the Answer happened and write down the new Answer
4. Repeat Step 3 until the team agrees that the Root Cause has been identified. - May take more or less than 5 Whys- Keep asking until you can no longer answer
12
The 5 Why Process
Sky Miltronics/Trust TechnologiesAugust 2009 13
Albatross Exercise
Sky Miltronics/Trust TechnologiesAugust 2009 14
Albatross Exercise Solution
Sky Miltronics/Trust TechnologiesAugust 2009
PROBLEM STATEMENT: MY CAR STOPPED WORKING ON THE WAY TO WORK
1. WHY DID YOUR CAR STOP WORKING? BECAUSE IT RAN OUT OF GAS
2. WHY DID YOUR CAR RUN OUT OF GAS?BECAUSE I DIDN’T BUY ANY GAS THIS MORNING
3. WHY DIDN’T YOU BUY ANY GAS THIS MORNING?
BECAUSE I DIDN’T HAVE ANY MONEY
4. WHY DIDN’T YOU HAVE ANY MONEY?BECAUSE I LOST IT ALL LAST NIGHT IN A POKER GAME
5. WHY DID YOU LOSE ALL YOUR MONEY IN A POKER GAME LAST NIGHT?
BECAUSE I AM NOT GOOD AT BLUFFING WHEN DON’T HAVE A GOOD HAND
SOLUTION: QUIT PLAYING POKER OR LEARN HOW TO BLUFF…
15
5 Why Example
Sky Miltronics/Trust TechnologiesAugust 2009
PROBLEM STATEMENT: Pizza Delivered Cold
1. Why was the pizza cold? It sat in the bag too long
2. Why was it in the bag too long? The driver got lost
3. Why did the driver get lost? He did not know the directions
4. Why did he not know the directions? He did not have a map
5. Why did he not have a map The Pizza company ran out of them
SOLUTION: Buy more maps and issue them to all drivers
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5 Why Example
Sky Miltronics/Trust TechnologiesAugust 2009 17
Flying Horses?
Sky Miltronics/Trust TechnologiesAugust 2009 18
Always Question Data
Sky Miltronics/Trust TechnologiesAugust 2009 19
How Does Trust-Mentor Currently Solve Problems?
Sky Miltronics/Trust TechnologiesAugust 2009
• Problem described incorrectly
• Problem Solving effort rushed through
• Poor Team Participation
• Lack of Technical Knowledge
• Poor Management Support
• Potential Caused misidentified as the Root Cause
• Corrective Action not implemented
20
Roadblocks to Effective Problem Solving
Sky Miltronics/Trust TechnologiesAugust 2009
• MANPOWER• MATERIAL• MACHINE• METHODS• MEASUREMENT
OTHER INFLUENCES CAN BE:
• MANAGEMENT (POLICES)• MONEY• ENVIRONMENTAL
21
Problem Influences
The 5 Ms
Sky Miltronics/Trust TechnologiesAugust 2009
Benefits:
• Easy to learn and Easy to use• A systematic approach • Challenges assumptions• Non-blaming and Non-judgmental• A team approach
Weaknesses:
• Tendency to stop short of true root cause
• Limited to current knowledge• Results are not always repeatable
22
The 5 Why Process
Sky Miltronics/Trust TechnologiesAugust 2009 23
5 Why - Real World Exercise
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