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The 5 Whys: A Practical Example January 21, 2014

The 5 Whys: A Practical Example January 21, 2014. Example Illustrated. The Missing Countersink. PN 123456. Countersink Missing. Countersink. What supplier delivered. Should be condition. Example Illustrated. The Missing Countersink. PN 123456. Purchase Order Requirement:

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The 5 Whys: A Practical Example January 21, 2014

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  1. The 5 Whys: A Practical ExampleJanuary 21, 2014

  2. Example Illustrated The Missing Countersink PN 123456 Countersink Missing Countersink What supplier delivered Should be condition

  3. Example Illustrated The Missing Countersink PN 123456 Purchase Order Requirement: C’sink dia: .409” +/- 0.010 .409”

  4. Five WhysLeg One Countersink missing from part Suggest what the next Why might be Drill press operator didn’t add countersink Suggest the next Why Job Traveler was missing instructions for countersink Suggest the next Why Planning lacked instructions for countersink Suggest the next Why Engineer Overlooked requirement for countersink on PO Suggest the next Why Engineer was going by memory of similar part without a countersink There is No Defined process for creating planning

  5. Five WhysLeg One Countersink missing from part Drill press operator didn’t add countersink Add countersink instructions to job Job Traveler was missing instructions for countersink Add countersink instructions to planning Planning lacked instructions for countersink Provide additional training to follow PO’s Engineer overlooked requirement for countersink on PO Engineer was going by memory of similar part without a countersink Create process for writing planning • There is No Defined process for creating planning

  6. 5 Why Leg Two Inspection process did not detect error on the part or in the planning Inspector checked the part against the job but not the drawing Inspectors haven’t been trained to inspect to the drawing Provide additional training There is no inspection plan with such a requirement Create an inspection plan

  7. 5 Why Leg Two Inspection process did not detect error in the planning The Planning wasn’t reviewed by Quality Assurance There is no requirement for QA to review new or updated planning There is no defined process for QA review of planning Create a planning review process to include QA

  8. 5 Whys – A Practical Example Questions?

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