5WhyTraining21OCT2010.ppt.pptVIP

3 Legged 5 Why Analysis Agenda When to Use 5 Why 3 Legged 5 Why Analysis 5 Why Examples Resources and References 5 Why and Customer Problem Solving Formats Where to Find the Blank Forms When to Use 5 Why Customer Issues Required for all Covisint Problem Cases May be requested for informal complaints May be requested for warranty issues Internal Issues (optional) Quality System Audit Non-conformances First Time Quality Internal Quality Issue 5 Why Analysis can be used with various problem solving formats Internal Problem Solving GM Drill Deep Ford 8 D (Discipline) Chrysler 8 Step 5 Why Analysis General Guidelines A cross-functional team should be used to problem solve Don’t jump to conclusions or assume the answer is obvious Be absolutely objective 5 Why Analysis General Guidelines Ask “Why” until the root cause is uncovered May be more than 5 Whys or less than 5 Whys If you are using words like “because” or “due to” in any box, you will likely need to move to the next Why box Root cause can be turned “on” and “off” Will addressing/correcting the “cause” prevent recurrence? If not what is the next level of cause? If you don’t ask enough “Whys”, you may end up with a “symptom” and not “root cause”. Corrective action for a symptom is not effective in eliminating the cause Corrective action for a symptom is usually “detective” Corrective action for a root cause can be “preventive” Path should make sense when read in reverse using “therefore” Problem Definition Define the problem Problem statement clear and accurate Problem defined as the customer sees it Do not add “causes” into the problem statement Examples: GOOD: Customer received a part with a broken mounting pad NOT: Customer received a part that was broken due to improper machining GOOD: Customer received a part that was leaking NOT: Customer received a part that was leaking due to a missing seal Specific Problem Specific Problem Why did we have the specific non-conformance? How was the non-conforma