What is Why Why ANALYSIS?

Why problem analysis is required?

→ The problem analysis is required to prevent the recurrence of the failure. → To find out the root_cause and we can easily take preventive action against that.

You can refer this article for better understanding of Various Problem Solving Methods → It is also very helpful for developing our problem_solving skills and mitigate future challenges.You can refer this article for better understanding of





What is the problem, cause, root cause, and countermeasure?

→ The problem is what has happened. or it is an undesirable event. → Issue Observation is an understanding of what has happened. → The cause is the reason behind the failure. → The root cause is exactly where the cause has originated. → Counter-measure: The action which you take against the root_cause so the issue will not be repeated again.

Key points of Why-why Analysis

How to perform Why-why analysis?

Idea of countermeasure

Example of 5 why analysis:

Benefits of 5 Why Analysis:

→ "Why-Why" analysis is an analytical method that is designed to help you identify all factors contributing to a problem one by one in an orderly fashion, rather than a hit-and-miss attempt to work out the factors and finally, we will have the root cause for the failure.→ Sakichi Toyoda developed this technique and firstly used it within the Toyota Motors.→ It is a critical component of problem_solving training and also the same was delivered as part of the induction training into the Toyota Production System for the newly joined employees.→ This method is also used during the implementing of, and→ Before going further we will discuss some fundamental concepts which are very important for understanding the 5 why method.→ 90% of problems can be solved only by why-why analysis.→ The remaining 10% of problems need a high level and complex methodology for solving.→ Understand the issue – observe the issue closely, at the spot, on the actual thing, collect all related information.→ Problem observation will lead to a conclusion→ The conclusion may lead to the root_cause or will lead to the starting of the 5 Why method.→ This method is a very famous👉 Refer to this article for→ It should be done in a team→ Verify facts from Genba – the real place, and on Genbutsu – the real thing.→ Connect the why-s in a chain of logic→ Should end up the investigation where the causes can be prevented→ Use the ‘hence’ logic to check the chain of logic is continuous→ No assumption, No guesses→ Keep management into the loop during the five whys process in the company.→ Use paper or whiteboard instead of computers because that is a more effective method.→ Write down the issue and make sure that all people understand it.→ Distinguish causes and symptoms. Don't mix up causes and symptoms.→ Keep the focus on the logic of cause_and_effect relationship.→ Try to make your answers more precise.→ Look for the cause step by step. Don't jump to the conclusions.→ Assess the process, not people.→ Never consider root_cause as "human error" or "worker's inattention".→ Ask "why" till the root_cause is determined.→ Repeat ‘why’ n-times (till root cause is found)→ Applicable for one single event→ Stop the why chain when you reach basic 5-causes→ Can be done by Gemba people based on actual findings→ It is not mandatory to stop after asking 5 why's sometimes we can reach at the root cause by less than 5 whys and sometimes it can go up to more than 5 whys.→ Countermeasure is just opposite of the root_cause identified→ Example:- No FG part checking standards are available in place- Establish and display the FG part checking standard at the FG part checking area.: Material was not reached at the site on time.→ Why-01: Why material was not reached on time?⇢ Ans-01: Because it was dispatched late.→ Why-02: Why material was dispatched late?⇢ Ans-02: Material was not ready on time.→ Why-03: Why material was not ready on time?⇢ Ans-03: Material specification reached late.→ Why-04: Why specification was reached late?⇢ Ans-04: Material specification was not sent with P.O.→ Why-05: Why specification was not sent with P.O.?⇢ Ans-05: Purchase person missed to send it together.→ Why-06: Why the person was missed to send it together?⇢ Ans-06: The purchasing person was new and he was not trained.: New persons’ training was not done. [Lack of Skill]: Introduce a training system for new joiners and after successful completion of the training the work will be allocated to the new joiner.→ Improving analytical thinking.→ Develop an understanding of the relation of the failure with theories & fundamental principles.→ Improve the knowledge of the function, structure, and mechanism of the equipment/process.→ Develop the consciousness about the abnormalities causing troubles in the workplace.→ Aim to level up the ability of the people.→ Develop the way of prevention of recurrence.