Why-Why Analysis Part Two

8/14/2019 Why-Why Analysis Part Two

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4. The pen doesnt work.

FIRST WHY:Why doesnt the ink flow over

the pens point?

Why does that happen?

a) Ink isnt reaching the pens point.

b) Theres no pressure on the ink to thepens point. (Gravity, others)

c) Theres nowhere for the ink to flow.

(The ballpoint is blocked.)

d) The ink doesnt flow over the other

surface.

(Writing in the air, or on ice, etc.)

. Establishing Cause-Effect Relationship.


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Steps for developing a

Why - Why Analysis:

Second Why For each answer to the Why? in the

previous step, the question Why? is

asked again.

The answer in this case, and from here on,

should consider the 4 - Ms.

. Establishing Cause-Effect Relationship.


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How to Verify Causes

Use the cause and effect worksheet as a guide Go look, listen, feel, ask - Watch with a purpose

Simulate

Make the fix (restore) and monitor

Do the verification on the floor

Use the safest, quickest, cheapest approach tha

fits your situation


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Problem

Why? 1

MissingCarton

Why? 2Seal

between

SuctionCup andCarton

inadequate

CartonsStickingTo EachOther

Holding

FingersMissAdjusted

HoldingFrame

TooTight

Why? 4

Duston

Carton

Scratcheson carton

SurfaceFinishoutside

tolerance

Why? 3

SuctionCup

Damage

PoorCartonSurface

Condition

VacuumSettingtoo low

VacuumLine

Leaks

SuctionCup

Too Small

SuctionCup

Wear

Field Check

No Wear

No Damage

Could be

Yes

Yes

Not True

No

No

Could be

Phenomenon

SuctionCup

InadequateMaterial

VacuumForceNot

HighEnough

ForcesHoldingCarton

toohigh

PullingForceNot

StrongEnough

Once you have exhausted your Why-Why Questioning, do the Cause-

Effect Relationships Make Sense and flow back to the Phenomenon ?

. Logical Review of the Analysis


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If we solve these causes, (1, 2, ...8)

is it possible that ZERO will be reached (Branch A)?

CAUSE # 1

Branch A

CAUSE # 2

CAUSE # 3

CAUSE # 4

CAUSE # 5

CAUSE # 6

CAUSE # 7

CAUSE # 8



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Repeat the question branch by branch until

the entire analysis has been verified.

BRANCH A

Main branch AA

BRANCH C

BRANCH D

BRANCH E

BRANCH F

BRANCH G

BRANCH H

BRANCH B



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. Checking for Standards and SOPs

Before taking counter measures, check to see if standards for the defined counter

measure exist. If not, define the standard. Determining if an SOP is needed.

Use the 4Ms to ensure all required types of standards exist.

Problem

Why

?

Why

?

Why

?

Why

?

Why?

Root

Cause

Std.

sExist?

Action

Taken?

Action

Standards(4Ms)

Man

Machine

Method

Material

SOP

Exist?

OK

NOK

XX

X

Applied?

F

i

e

l

d

C

h

e

c

k

Y

N

Y

N Restore

New

Std.

NewMaint.Std.

YN

WHY-WHY


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Analysis Steps

i. 1. Understanding the Problemii. 2. Defining the Phenomenon to be analyzed.iii. 3. Establishing Cause-Effect Relationship through Why

questioning and Field Checks.

iv. 4. Logical Review of the Analysis

v. 5. Checking for Standards and SOPs


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Notes and Advice:

The analysis should be done at the problem area,not in another location that is isolated from the case

The analysis is a team effort, not by just one perso

The most important thing is the physical and/or

logical description of the phenomenon to be studied

(Step 1) The Analysis ends when countermeasures TO

AVOID RECURRENCE of the phenomenon are

found.


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ALWAYS make a sketch or drawing of the phenomenon

The 4-Ms dont always apply to every cause to beanalyzed, but we should always consider them so as noto forget possible causes of causes.

The more simplicity and objectivity in steps 1 and 2, theasier it is to ensure that all possible causes arecovered.

Practice develops skill.This tool makes us more objective in our way of lookinat things.

Notes and Advice:


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Why/Why - NOT!!!

Problem Why Why Why Why Why Action Plan

Already had the answer,

used the tool to document it

Brainstorming,

in a room,

no verification


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Real WHY-WHY Analysis Example

Problem: Through put of the line 23 is below ideal.

Phenomena: Carton not Picked off the supply stack.

Result: This causes a loss in through put. (Missing Carton)

MissingCarton


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Phenom

enon

Why

?

1

MissingCarton

PullingForceNot

Strong

Enough

ForcesHoldingCarton

toohigh


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Why? 1

MissingCarton

PullingForceNot

Strong

Enough

ForcesHoldingCarton

toohigh

Why? 2 SealbetweenSuction

Cup andCarton

inadequate

Vacuum

ForceNotHigh

Enough


Holding

FingersMissAdjusted

HoldingFrame

TooTight

Phenomenon


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Why? 1

MissingCarton

PullingForceNot

Strong

Enough

ForcesHoldingCarton

toohigh

Why? 2 SealbetweenSuction

Cup andCarton

inadequate

Vacuum

ForceNotHigh

Enough


Holding

FingersMissAdjusted

HoldingFrame

TooTight

SuctionCup

Wear

Why? 3

SuctionCup

Damage

PoorCartonSurface

Condition


VacuumLine

Leaks

SuctionCup

Too Small

SuctionCup

InadequateMaterial

LooseCartonStack

Flapsfolded

Backward

P

om

o


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Why? 1

MissingCarton

PullingForceNot

StrongEnough

ForcesHoldingCarton

toohigh

Why? 2Seal

betweenSuction

Cup andCarton

inadequate

VacuumForceNot

HighEnough


HoldingFingers

MissAdjusted

HoldingFrame

TooTight

Why? 4

Duston

Carton

Scratcheson carton

SurfaceFinish

outside

tolerance

Why? 3

SuctionCup

Damage

PoorCartonSurface

Condition


VacuumLine

Leaks

SuctionCup

Too Small

SuctionCup

InadequateMaterial

SuctionCup

Wear

LooseCartonStack

Flapsfolded

Backward

P

om

o


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Why? 1

MissingCarton

PullingForceNot

StrongEnough

ForcesHoldingCarton

toohigh

Why? 2Seal

betweenSuction

Cup andCarton

inadequate

VacuumForceNot

HighEnough


HoldingFingers

MissAdjusted

HoldingFrameToo

Tight

Why? 4

Duston

Carton

Scratcheson carton

SurfaceFinish

outsidetolerance

Why? 3

SuctionCup

Damage

PoorCartonSurface

Condition


VacuumLine

Leaks

SuctionCup

Too Small

SuctionCup

Inadequate

Material

SuctionCup

Wear

Field Check

Not worn

Not Damag

Could be

No Dust

Not true

Problem

Found to be

Some Leak

Correct Size

Phenome

non


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y

WHY-WHYProb

lem

Wh

y?

Wh

y?

Wh

y?

Wh

y?

Why?

Root

Cau

se

Std.s

Exist?

Act

ion

Tak

en?

SOP

Ex

ist?

Appl

ied?

F

i

e

ld

C

h

e

c

k

Duston

Carton

Scratcheson carton

Surface

Finishoutsidetolerance

SuctionCupDamage


VacuumLine

Leaks

SuctionCup

Too Small

SuctionCup

InadequateMaterial

SuctionCup

Wear

Ntrue

Ntrue

True

True

True

NTrue

Y

Y

N

Standards(4Ms)

hu

Man

equipM

Method

Mat

erial

XX

X

XX

X

X

NN

Appl

ied?

Tra

DevSt

YYY Develop SOP

Tra


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Another example:

General Problem:

Five Port Valve

Air cylinder

Air piston moving too slow

in both directions


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Draw the problem


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Get an understanding of the process:

Drawing, Parts, Process

Exhaust

Five Port Valve

Adjustable

Restrictor

Air cylinder

Bottom

seal

Rod seal

Bush

Pipes P0


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Get an understanding of the process:

Drawing, Parts, Process, Forces, Counterforces

Exhaust

Five Port Valve

Adjustable

Restrictor

Air cylinder

Bottom

seal

Rod seal

Bush

Pipes P0

Forces

Counterforces


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Piston slow

moving in Both

irections

Phenomena 1. Why 2. Why 4. Why 5. Wh3. Why

Conduct Why/Why


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Piston slow

moving in both

irections

Defect 1. Why

1. 1 Force (pressure)

too low

1. 2 Counterforce

too high

2. Why 4. Why 5. Wh3. Why

Fie

ld

Verification

Not True

True

Conduct Why/Why


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Defect 1. Why


too low

1. 2 Counterforce

too high

2. Why

1.1.1 pressure p0

too low

1.1.4 adjustable

restrictor closed

1.1.2 5 port valve

defect

4. Why 5. Wh3. Why

1.1.3 blocked pipe

1.1.5 air leakage

Fiel

d

Verification

Not True

True

Not True

Not True

Not True

Piston slow

moving in both

irections

Conduct Why/Why


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Defect 1. Why


too low

1. 2 Counterforce

too high

2. Why

1.1.1 pressure p0

too low

1.1.4 adjustable

restrictor closed

1.1.2 5 port valve

defect

4. Why3. Why

1.1.3 blocked pipe

1.1.5 air leakage

Piston slow

moving in both

irections

1.1.1.1 not adjusted

after c/o to

shampoo

1.1.1.2 Air leakage

Field

Verification

True

Not Tr

Conduct Why/Why


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Defect 1. Why

1. 1 Force

(pressure)

too low

1. 2 Counterforce

too high

2. Why

1.1.1 pressure p0

too low

1.1.4 adjustable

restrictor closed

1.1.2 5 port valve

defect

4. Why3. Why

1.1.3 blocked pipe

1.1.5 air leakage

Piston slow

oving in both

rections


after c/o to

shampoo

1.1.1.2 Air leakage

1.1.1.1.1 No Procedure

1.1.1.1.2 Lack ofKnowledge

F

ield

Verification

Conduct Why/Why


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4. Why3. Why


after c/o to

shampoo

1.1.1.2 Air leakage

1.1.1.1.1 No Procedure

1.1.1.1.2 Lack of

Knowledge

Possible Counter measures

- Develop Procedure

- Retraining, One Point Lessons etc

- Visual controls to make easierto see if off...

Conduct Why/Why


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Case StudyWhy-Why Analysis

Problem Description Problem Picture Phenomenon

Company A is located on the 30th floor of a

high-rise building. Customers often complainthat elevators are slow in coming, and there is

a fear that it may have an adverse effect on the

company's sales performance.

A study revealed that more visitors come to the

company between 13:00 and 15:00 hours and

that their waiting time averages around 30 sec.

Please solve this problem by appling why-why

analysis

Problem Statement What does success look like?

Phenomenon Why (1) Why (2) Why (3) Why (4) Why (5) Countermeasures

Have you verified the cause?


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WHY - WHY ANALYSIS

REVIEW VS. OBJECTIVES:

Understand the definition of Analysis

Clarify the procedure for developing a Why - Why

Analysis.

Stress the importance of each step of the Why - Why

Analysis.

ELIMINATION

OF LOSSES


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MaintenanceCircleTeam Page 1 November 16th , 2009

Maintenanc

If you like to improvise this article or contribute or comment please mail us at:[email protected]

This document contains information for reference only. We assume no responsibility for its implication.

Maintenance circleNNEEWWSSLLEETTTTEERR FFOORR MMAANNUUFFAACCTTUURRIINNGG CCOOMMMMUUNNIITTYY

Solution for Last week Techuzzle

Across

5. LEAST COUNTExpand LC, commonly used in measuring instruments7. FISHBONECommon name for Ishikawa Diagram is _____ Diagram

Down1. HISTOGRAMChart which looks like tall buildings next to each other2. PROCESSP stands for _____ in SPC3. ASSURANCEA stands for _______ in QA4. CONTROLC stands for ______ in QC5. LIMITL stands for _____ in LCL or UCL6. ANALYSISA stands for _____ in RCA

1 2 3 4

5 6

7

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mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Maintenanc

If you like to improvise this article or contribute or comment please mail us at:[email protected]

This document contains information for reference only. We assume no responsibility for its implication.


Solution for Quality Month Special Techuzzle

Across

1. MILLIONSix Sigma implies appearance of 3.4 defects per ____ (Million, Billion, Thousand)5. SEVENBroadly, how many steps are involved in Six Sigma Methodology (Ten, Seven, Twelve, Six)7. MIKEL HARRYThis person founded Six Sigma Academy (Mikel Harry, Jurong, Taylor)

Down1. MOTOROLAThis company was instrumental in developing Six Sigma Concepts (Motorola, Mercedes, Ford)2. BLACKSecond Belt of Six Sigma3. DEVIATIONSigma, in statistics, is a basic indication of Standard _____ (distribution, deviation, dispersion)4. CHAMPIONThird (FInal) Level of Six Sigma6. GREENFirst Belt of Six Sigma

1

2 3

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mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Maintenanc


This week Techuzzle

Across

2. H stands for _______ in RoHS, an environmental standard4. S stands for ______ in MSDS supplied with many materials8. ISO 14644 standard is common referred to as ______ standard

Down

1. This is the ISO standard for ambient air quality3. TS 16949 is the widely used standard for _______ sector5. ISO 22000 integrates _____ standards for food industry6. ISO 147 explains standards for _____ quality7. I stands for ________ in AIT, one of the important part of ISO 14000 environment standards

1

2 3

4

5

6 7

8

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Why-Why Analysis Part Two

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