JH - Why-Why Training Module

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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Why-Why Analysis Training Module

To learn the technique of determining the root

• Root cause is the factor that caused a

• Root cause analysis (RCA) is a sequential and

•Use factual data

• The team must fully understand the problem prior

• Look beyond the obvious and immediate solutions

•Do not confuse “Symptoms” and “Causes”

• Symptom is a manifestation of a cause

• Cause is the factor which when removed, the

• Time and schedule pressures

• Attractiveness of an immediate fix

• Lack of thorough understanding of the problem

• Lack of recompilation of the events that occurred

• Failure to document data as evidence of the problem

• Lack of team approach

• Lack of training in performing root cause analysis

• Errors and mistakes in executing established

• Inadequate steps and wasteful measures

• Variation in inputs to the process

• Poor Operating Condition : A situation when the

• Deterioration : A situation derived out of natural &

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

• Immediate corrective actions are not necessarily

• Immediate corrective actions are needed to avoid

Eg: Lubricated the Cylinder rod.

• Use only one subject while describing a phenomena.

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