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Problem Solution - 5 Why's Analysis
It helps to quickly identify the root cause of a problem.It
helps determine the relationship between different root causes of a
problem.
It can be learned quickly and doesn't require statistical
analysis to be used.
When Is 5 Whys Most Useful?
When problems involve human factors or interactions.
In all types of business situations whether solving a lean
manufacturing or for any other business problem.
1. Why is our largest customer unhappy? Because our deliveries
of bicycles have been late for the last month.
. Why have our bicycle deliveries been late for the last month?
Because production has been behind schedule.
!. Why has production been behind schedule? Because there is a
shortage of wheels.
". Why are we having a shortage of wheels? Because incoming
inspection has re#ected a large number of wheels for not being
round.
$. Why are we re#ecting so many parts? Because purchasing
switched to a cheaper wheel supplier that has inconsistent
quality.
$ whys as part of lean manufacturing is a problem solving
technique that allows you to get at the root cause of a problem
fairly quickly. It was made popular as part of the
Benefits Of The 5 Whys.
!am"le of a fi#e Why Analysis. ...$ere is our %&heel% life
e!am"le.
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Problem Solution - 5 Why's Analysis Worsheet
Part (umber) *ate) Area) P
Problem *es,ri"tion)
Use this route to s"e,ify the non,onformity that is bein
in#estiate+. /oot 0auses
%herefore
the operator picked it not knowing it,s a wrong
item%herefore
Why?
the incorrect item was placed on the locati %herefore
Why?
%herefore A
Why?%herefore
%hereforeWhy?
%hereforeWhy?
Why?
%herefore
Why?%herefore B
Use this route to in#estiate the root ,ause of the system.
Why?%herefore
%hereforeWhy?
%hereforeWhy?
Why?%herefore
Why?%herefore 0
Why?%herefore
Why?
Why?
Why?
Use this route to in#estiate &hy the "roblem
&asn2t+ete,te+
Why?
Why?
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%oyota &roduction ystem (1)*
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*ate
Im"lementation *ate)
A,tion 1sibility
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3i hb
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3ishbone
/oot 0ause I+entifi,ation Tool
4,om"lete for "ro+u,t in#ol#e+ in uality issue6
0ause an+ ffe,t 43ishbone *iarams6
cause and effect (fishbone- diagram2
3 Breaks problems down into bite0si4e pieces.
3 5isplays many possible causes in a graphic manner.
3 Is also called a cause 6 effect7 "08 or Ishikawa diagram.3
hows how various causes interact.
3 9ollows brainstorming rules when generating ideas.
ProbStatem
Ma,hine
Metho+
Material
Man"o&er
Man
n#ironment
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IS-IS (OT MAT/I:
Problem) Is Is (ot *istin,tions
!tent of "roblems
Who is in#ol#e+?
What o,,urs; &hat ob
