Sunday 2 December 2018

5 Why Analysis: Finding the Roots of a Problem

5 Why Analysis is the tool (tool) root cause analysis for problem solving. This tool helps identify the root cause or cause of a discrepancy in the process or product.

Why-Why Analysis or 5 Why's Analysis is used in conjunction with Fishbone Diagram and use the iteration technique by asking WHY (Why). It should repeat several times until it finds the root of the problem. And then performs an improvement.

Examples are as follows:

Problem: Machine Breakdown / Damage.

  1. Why? The automaton component does not work.

  2. Why not work? The component's age has exceeded the 12-month lifetime limit.

  3. Why not be replaced when it reaches the limit? No one knows the lifetime limit of that component.

  4. Why does nobody know? There is no recording of component replacement data.

  5. Why is there no record? Well, in fact we have arrived at one of the potential root causes of the problem, ie the absence of recording of component replacement data.

To arrive at the root of the problem, either on the fifth question or even more or less depending on the type of problem.

General stage when doing root cause analysis with why-why analysis:

  1. Determine the problem and the problem area

  2. Bring together a team for brainstorming so we can have different views, knowledge, experiences, and approaches to the problem

  3. Perform Gemba (down to the field) to see the actual area, the actual object, with actual data.

  4. Begin to ask using 5 Why

  5. Once you get to the root of the problem, test each answer from the bottom if the answer will have an impact on the top level. Example: if we have recording of replacement component it will be easy for Team Maintenance to do component replacement regularly? Does it make the most sense to cause an impact at the top level? Are there alternatives to other causes?

  6. In general, the solution does not lead to blame to the person but how to do the repair system or procedure.

  7. If the root cause is known, then immediately identify and implement the solution.

  8. Monitor keeps performing to ensure that the problem does not recur.

It may be a favorite question to ask "why" or "why this is" for small children who want to know more about things in this world.

Conclusion from Analysis

But the question of technology can be a powerful technique for why or why it can solve the problem of finding the root cause of repetitive problems. Engineering question "why" does not require the analysis of difficult techniques such as hypothesis, reaction or correlation. But this technology needs to have an approach of principle of the flow of "logic" drilled sharp at the root of the problem.

Example for  5 Analysis Techniques (5 Why)

Problem: The discovery of the delivery model for the wrong customers

Chapter 1: Why is the wrong delivery model for customers?
Because there was an error recovering from the logistics staff

Chapter 2: Why is the error in taking out the logistics employees?
Due to logistics staff there is no bar code scan on the box which will be sent.

Chapter 3: Why does logistics staff not be scan by a bar code system on a box that will be distributed?
Because the computer use for a bar code scanner can be broke at the moment.

Chapter 4: Why is a computer used for a bar code scanner broken?
Because the computer is use for sudden death scanners.

Chapter 5: Why do computers used for these scanners die suddenly?
Because the power supply suddenly shut down.

From Question 5 Revolution, the destruction of power supply is the root cause of incorrect delivery problems. So, the necessary precautions are so that it does not happen again.

Examples of actions by adding backup power supply or UPS to a computer such as a question can be add to the computer. So that when an electrical scanner is use the electrical current is destroy. Or at least still has time to shut down. On a Computer Scanner

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