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JH - Why-Why Training Module

This document provides training on why-why or root cause analysis. It defines why-why analysis as a scientific inquiry tool used to determine the root cause of problems or phenomena. The document outlines general rules for performing root cause analysis like using a team approach and factual data. It also discusses constraints like time pressures. Case studies are provided as examples. Do's are listed such as pursuing why questions until you find a preventative cause.

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shariq warsi
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602 views24 pages

JH - Why-Why Training Module

This document provides training on why-why or root cause analysis. It defines why-why analysis as a scientific inquiry tool used to determine the root cause of problems or phenomena. The document outlines general rules for performing root cause analysis like using a team approach and factual data. It also discusses constraints like time pressures. Case studies are provided as examples. Do's are listed such as pursuing why questions until you find a preventative cause.

Uploaded by

shariq warsi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Why-Why Analysis Training Module

Why-Why Analysis
Learning Objectives

To learn the technique of determining the root


cause of the problem being analyzed thro 5 Why
or Why-Why Analysis.

Why-Why Analysis
Topics

• Definition
• General rules
• Constraints
• Immediate corrective actions
•Case Studies
• Root cause analysis Do’s

Why-Why Analysis
What is Why‐Why Analysis ?
•It is a scientific enquiry tool 

• Also referred to as Root Cause Analysis

• It is a method of “Questioning”

• It leads to the “Root Cause” of the 
problem/phenomena.

Why-Why Analysis
Root Cause Analysis definition

• Root cause is the factor that caused a


breakdown,defect,accident or
nonconformance

• Root cause analysis (RCA) is a sequential and


investigative process used to determine the
root cause of the problem

Why-Why Analysis
General rules to perform root cause
analysis
•Team effort

•Use factual data

• The team must fully understand the problem prior


to starting the analysis

• Look beyond the obvious and immediate solutions

Why-Why Analysis
General rules to perform root cause analysis

•Do not confuse “Symptoms” and “Causes”

• Symptom is a manifestation of a cause

• Cause is the factor which when removed, the


problem is cured

Why-Why Analysis
Constraints

• Time and schedule pressures


• “Fire-fighting” mode

• Attractiveness of an immediate fix

• Cost considerations

• Lack of thorough understanding of the problem


• Confusing symptoms versus causes

Why-Why Analysis
Constraints (continuation)
• Lack of documentation, data or information on how
the problem occurred

• Lack of recompilation of the events that occurred


before the problem.

• Failure to document data as evidence of the problem

• Lack of team approach

• Lack of training in performing root cause analysis

Why-Why Analysis
Root Causes
Sourcesof how the process works or
•Inadequate knowledge
should work

• Errors and mistakes in executing established


procedures

• Inadequate procedures

• Inadequate steps and wasteful measures

• Variation in inputs to the process

Why-Why Analysis
Root
•Poor Basic Condition
Causes: A situation derived out of
absence of certain basic requisites like missing Nuts,
Grub Screws, etc.

• Poor Operating Condition : A situation when the


machine is operated under strained conditions like
overloading of Motor, increased temperatures lack of
lubrication , lack of lubrication than normal etc.

• Deterioration : A situation derived out of natural &


forced deterioration like Oil Seal worn out, O ring has
become brittle .
Why-Why Analysis
Root
Causesderived out of inherent
•Weak Design: A situation
flaws in the design & construction of the equipment
like slipping of coupling due to absence of flat surface
on shaft for grub screw locking.

• Poor Skill: A situation when the cause is derived due


to non adherence of procedures due to lack of skill &
lack of knowledge. Typical examples are failure due to
use of wrong lubricant by Operator, use of wrong
hand tools while fitment of sub-assemblies.

Why-Why Analysis
Immediate Fix (Final
Action)
• They are developed and implemented to “cure”,
or alleviate the problem momentarily, while the
root cause is investigated

• Immediate corrective actions are not necessarily


root cause corrections

• Immediate corrective actions are needed to avoid


major cost impact

Why-Why Analysis
Immediate Fix (Final Actions)…
(continuation)
• Benefits
• It is quick
• Does not take too much effort to develop
• Inexpensive
• Keeps management happy
• It saves the process from being shut down

Why-Why Analysis
Immediate Fix (Final Actions)….(continuation)

• Disadvantages:
• Not process oriented
• Because of time constraints, it lacks thorough
analysis
• Usually, it is one person opinion
• Misinterpreted cost effectiveness
• Often, lacks data and documentation

Why-Why Analysis
What is a Physical
Phenomena ?
A Physical Phenomena is defined as the final,
noticeable, visible effect of a non-conformance or
abnormal happening . It can be seen or felt by the 5
human senses like vision, sound, feel, taste or
smell.
e.g. 1.Pneumatic Cylinder not Operating.
2. Burning Smell from Motor.
3. Abnormal noise from Gear Box.

Why-Why Analysis
What is a Final
It is that action taken as an immediate fix due to
Action?
which the physical phenomena observed is
corrected or eliminated.

Eg: Lubricated the Cylinder rod.


Applied Varnish to the Stator Windings.
Replaced the Spider of Coupling of Gear Box.

Why-Why Analysis
What are
Countermeasures?
Process out of Control

Action Taken is
Countermeasure UCL

LCL
Process under Control

Why-Why Analysis
Why-Why Analysis
Case Study – Why-Why Analysis

Why-Why Analysis
Case Study – Why-Why Analysis

Why-Why Analysis
Do’s for Why-Why Analysis

• Use only one subject while describing a phenomena.


Phenomena statement should not contain combination of
problems.
• When answering the first “Why” focus on the direct cause
of the phenomena.
• Try to correlate by reading all Why’s in backward
direction.Check whether the argument holds true !!
• Avoid an answer such as Inattentiveness, busy or lack of
attention.
• For getting results do Why-Why on Gemba. Pursue the
Why’s till you arrive at such a cause that will prevent
recurrence.
Why-Why Analysis
Exercise !!

Why-Why Analysis
Thanks for your attention !!

Why-Why Analysis

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