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Solving the Deeper Why’s Creates Permanent Gains

Solving the Deeper Why’s Creates Permanent Gains. Problem Statement: Wrong item shipped to customer. “Retrain our stock pickers” – almost no benefit – this solution has nothing to do with the true cause. “Inspect our inventory” – minimal benefit – applies to current stock only.

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Solving the Deeper Why’s Creates Permanent Gains

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  1. Solving the Deeper Why’s Creates Permanent Gains Problem Statement: Wrong item shipped to customer “Retrain our stock pickers” – almost no benefit – this solution has nothing to do with the true cause “Inspect our inventory” – minimal benefit – applies to current stock only “Have the supplier sort their stock to contain the problem” – very limited long-term benefit “Conduct training at the supplier” – limited long-term benefit “Mistake-proof the label printing and application process” – highly effective

  2. 5-Why Analysis – ABC Distribution Center Problem Statement: Wrong item shipped to customer The wrong item was pulled from inventory Why? The item we pulled from inventory was mislabeled Why? Our supplier mislabeled the item prior to shipping it to our warehouse Why? The individual applying labels to our product at the supplier placed the wrong label on the product Why? Labels for different orders are pre-printed, and it is easy to apply the wrong label Why?

  3. 5-Why Analysis For Multiple Causes Problem Statement: Downtime in Final Assembly is Averaging 22 Minutes Per Shift, Versus the 5 Minute Goal Why? Why? Why? Why? Why? Machine XYZ Capacity Constraint Two of Six Stations not Functioning Supplier “A” Capacity Constraint Lack of Preventive Maintenance 35% of Pareto 1 Material Shortages Lack of Training and Internal Audit Suppliers not Monitoring Bin Status Kan-Ban Bins Empty 14% of Pareto Bearing Replacement Not in Preventive Maintenance Program Missed the Bearings in Original PM Needs Assessment ABC Machine Down for Constant Adjustments Alignment Problems Bearings Worn 2

  4. 5-Why Analysis For Multiple Causes Problem Statement: Downtime in Final Assembly is Averaging 22 Minutes Per Shift, Versus the 5 Minute Goal Why? Why? Why? Why? Why? AJ – 1/27 Target Machine XYZ Capacity Constraint Two of Six Stations not Functioning Supplier “A” Capacity Constraint Lack of Preventive Maintenance 35% of Pareto 1 Material Shortages Lack of Training and Internal Audit Suppliers not Monitoring Bin Status Kan-Ban Bins Empty Complete Review of PM System (JB) – 3/12 Report-Out Scheduled Need Owner & Target Date 14% of Pareto Bearing Replacement Not in Preventive Maintenance Program Missed the Bearings in Original PM Needs Assessment ABC Machine Down for Constant Adjustments Alignment Problems Bearings Worn 2

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