7217166 Why Why Analysis

8/13/2019 7217166 Why Why Analysis

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WHY - WHY ANALYSIS

TRAININGOBJECTIVES:

To understand the definition of Why - Why Analysis.

To clarify the procedure for deelopin! a Why - Why

Analysis.

To stress the i"portance of each step in the Why -Why Analysis.

CO#$SE SCO%E & J#STI'ICATIO(:

Why-Why Analysis is a )asic* funda"ental tool in the

deelop"ent of the IWS cornerstones* so it is essential

that each +eader in the i"ple"entation of IWS ,no

this techniue and trans"it it to his&her or, tea"s.


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W/0 - W/0 A(A+0SIS

What is Why-Why Analysis1

It is a tool to identify root causes of a pro)le"

so that counter"easures can )e applied to

preent reoccurence.

Why-Why %rocess:

Basically the process is to ,eep as,in! hy

for all possi)le causes until you can find the

root cause for each effect and* therefore* find

a counter"easure for each root cause.


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Why-Why Analysis

A different ay to or!ani2e Cause and

effect relationships.

3ore efficient after a Cause and effect

Analysis

4one on the %riority ite"s found in a

Cause and Effect Analysis.


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/o do tools fit1

Effect

HuMan Machine

MethodsMaterial EnvironMent

Cause Effect

Tye of !hec" !hec" #etails

5. 4irect O)seration

6. Eidence fro" collected data

7. E8pert9s e8perience

. Theory

;. Others

Thesis

Already existing reference standard !hec" $ethod to %eused

Already existing Control Method Results of the chec"

Verify e8istence of cause and

effect for this situation

Cause and Effect Wor,sheet

%ro)le" Why Why Why Why Why


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What is the &roduct of a Why-Why Analysis '

It is a structured( field chec"ed( relationshi )ith each

cause-effect relationshi lin"ed fro$ the lo)est

ele$ent %ac"

to the

heno$enon*

h

y

'

Wh

y

'

Wh

y

'

h

y

'

Why' Std*+

s

i i

Standards.M+s/

hu

an

e0

ui

e

thod

a

terial

S1&

i

True

NTrue

22

2

Alied'

3

i

e

ld

!

h

ec

"

Y

N

Y

N Restore

Ne)

Std*Ne)Maint*Std*

YN

WHY-WHY

NTrue


7/66

Let+s 4rea" the Analysis

into the 3ollo)in5 Stes5. #nderstandin! the %ro)le"

6. 4efinin! the %heno"enon to )e analy2ed.7. Esta)lishin! Cause-Effect $elationship

throu!h Why uestionin! and 'ield Chec,s.

. +o!ical $eie of the Analysis;. Chec,in! for Standards and SO%9s


8/66

+et9s See What9s !oin! on1

1. The light bulb

doesnt go on

2. He slipped

. The !atch

doesnt light

". The pen

doesnt

#rite

Ti$e6 78+

7* 9nderstandin5 the &ro%le$


9/66

#nderstandin! the pro)le"

= 'or" a tea" of ualified*,noled!ea)le people.

= 4eelop a !eneral description of the

pro)le".= 4eelop an initial pro)le" state"ent.


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Ho) you focus on the&ro%le$ Greatly i$acts the

success of the Analysis*



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a$ According to the %rocess or &or' (lo# re)uire!ents.

b$ According to the physical causes.

T)o !larifyin5 aroaches



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*dentify those conditions re)uired by the%rocess to correctly operate and chec' all of

the! before start doing the analysis.

+Chec'list$

Ad,antages-

/i!plerMore practical

(aster

Accordin5 to &rocess or Wor" 3lo) re0uire$ents



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*dentify the !echanics that generates the

pheno!enon and start the analysis based on it.

Ad,antages-More co!plete

More precise

More effecti,e

This !aterial considers this

approach as the standard #ay to

perfor! #hy0#hy analysis.

Accordin5 to hysical causes*



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4efine the the %heno"enonWe intend to define the "echanics that

!enerate the pheno"enon* in other ords* theay or process throu!h hich hat e are

descri)in! occurs.

Brea, the pro)le" don into specific*

o)sera)le pheno"ena.Ali!n the tea" on hat success loo,s li,e.

6. 4efinin! the %heno"enon to )e analy2ed.


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%ro)le" s %heno"enon E8a"ple

&ro%le$6 The roo$ is too dar"

4etter6 The li5ht %ul% :doesn+t 5o on;

4est6 There is no flo) of electric current throu5h

the fila$ent


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%ro)le" s %heno"enon E8a"ples

E,a$les &ro%le$s' &heno$ena'

&rocess relia%ility is %elo) ounces er %ottle

The fa$ily car is )orn out

The en5ine is usin5 one 0uart of oil every ?88 $iles

The car seats are ried


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Scoto"a Trainin!

4efinition

Scoto"a literally "eans >li"ited ision ithin our

field of ision.? It is used to e8plain the fact that eso"eti"es see hat e e8pect to see.

/o it lin,s to this trainin!

Scoto"as can ,eep us fro" reco!ni2in! the

causes to so"e pro)le"s. We "i!ht not een

reco!ni2e the pro)le". @+i,e the ay e oerloo,

defects if e hae !otten to the point here e

consider the" as nor"al.


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What9s the pro)le"1


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What9s the pro)le"1


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What9s the pro)le"1


24/66

What9s the pro)le"1


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What9s the pro)le"1

What does Success Loo" Li"e'

6 4 fi i th %h t ) l d


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What9s !oin! on1

4efine each of the folloin! pheno"ena:

1. The light bulb

doesnt go on2. He slipped

. The !atch

doesnt light

". The pen

doesnt

#rite

Wor"5rou activity ./

Ti$e6 78+




27/66

What9s !oin! on1

1. The light bulb doesnt go on

The pheno!enon that produces light

is the heating of the fila!ent #henelectrons or electric current flo#s

through it.

/C3*%T*45 4( TH %H54M545-

There is insufficient or no flo# of electric

current through the fila!ent.




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What9s !oin! on1

2. He slipped

/lipping occurs #hen the force of

friction is less than the force that

caused hi! to slide.

3 @ I$ulse that caused

hi$ to slide*

f @ 3orce of friction /C3*%T*45 4( TH %H54M545-

( 6 f




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What9s !oin! on1. The !atch #ont light

*n order for a !atch to light7

conditions need to be !et-

a$ (uel.0 Met #ith the stri'ing

!aterial and the !atch head. +48.$b$ 4xygen.0 %ro,ided by the

en,iron!ent. +48.$

c$ Heat.0 Caused by the friction of

the !atch head against the rough

strip on the !atchbox.

/C3*%T*45 4( TH %H54M545-

There is not enough friction bet#een the !atch head

and the rough strip on the !atchbox to produce the

heat needed for ignition.




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What9s !oin! on1". The pen doesnt #or'.

*n order for the pen to #rite7 in'

needs to flo# to the pens ballpoint

and o,er it onto a surface#here it is deposited.

/C3*%T*45 4( TH %H54M545-*n' doesnt flo# o,er the pens point.


7 Esta)lishin! Cause Effect $elationship


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'irst >Why? a)out the %heno"enon

This uestion needs to )e ansered fro" aphysical and&or lo!ical point of ie.

The uestion needs to )e ansered for each

ele"ent inoled in the description "ade in the

preious step.At this point* focus on the eidence of the flas*

that is:

a/ erify the evidence of the causes of the ro%le$ in

the field )hether it e,ists or not( stoin5theanalysis for that %ranch )hen the cause doesn+te,ist/*

%/ If it is ossi%le to ut a direct counter$easure to

the cause into lace( do it and sto the analysis

ensure that rocedures or standards are in lace to$aintain condition achieved*.

7. Esta)lishin! Cause-Effect $elationship.



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Why does it happen1

As, the first >Why1? uestion and anser it for each

pheno"enon.

1. The light bulb

doesnt go on2. He slipped

. The !atch

#ont light

". The pen

doesnt

#or'

Wor" 5rou activity ./

Ti$e6 7?+




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Why does that happen11. The light bulb doesnt go on

(*3/T &H9-

&hy is the flo# of electric current

through the fila!ent insufficiento non0existent:

+The flo# of electric current in a flo#

of free electrons in the !aterial$.

a/ There aren+t any free electrons in the $aterial The fila$ent $aterial is a dielectric/

%/ There+s no ener5y to $ove the electrons

c/ There is not enou5h ener5y

d/ There is no)here for the electrons to flo)

The fila$ent is %ro"en/

Eli$inated %y

evidence*




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2. He slipped

3 @ I$ulse that rovo"es the slide*

f @ 3orce of friction

(*3/T &H9-

&hy is ( 6 f :

4;/3


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. The !atch #ont light(*3/T &H9-

&hy is there not enough friction bet#een the !atch

head and the !atchbox strip to produce the heat

needed to cause ignition:

Why does that happen1

+*n this case of friction7 #hat is

i!portant is that heat be generated$

a$ The pressure applied bet#een the !atch and the

!atchbox is too lo#.

b$ The surface of the !atchbox is not rough enough.

c$ The surface of the !atch head is not rough enough.

d$ There is a lubricant bet#een the surfaces.

e$ The friction duration is not long enough to heat the

!atch head and produce ignition.




36/66

". The pen doesnt #or'.

(*3/T &H9-

&hy doesnt the in' flo# o,er

the pens point:

Why does that happen1

a$ *n' isnt reaching the pens point.

b$ Theres no pressure on the in' to the

pens point. +=ra,ity7 others$c$ Theres no#here for the in' to flo#.

+The ballpoint is bloc'ed.$

d$ The in' doesnt flo# o,er the other

surface.

+&riting in the air7 or on ice7 etc.$




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Steps for deelopin! a

Why - Why Analysis:. Second >Why?

'or each anser to the >Why1? in the

preious step* the uestion >Why1? isas,ed a!ain.

The anser in this case* and fro" here on*

should consider the > - 39s.?



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/o to Verify Causes

#se the cause and effect or,sheet as

a !uide

Watchith a purpose?

Si"ulate

3a,e the fi8 @restore and "onitor

Do the verification on the floor

+o!ical $eie of the Analysis


39/66

&ro%le$

Why' 7

MissingCarton

PullingForceNot

StrongEnough

ForcesHolding

Cartontoohigh

Why' >Seal

betweenSuction

Cup andCarton

inadequate

Vacuum

ForceNotHigh

Enough

CartonsStickingTo Eachther

HoldingFingers

Miss!d"usted

HoldingFrame

TooTight

Why' .

#uston

Carton

Scratcheson carton

Sur$aceFinish

outsidetolerance

Why' B

SuctionCup

#amage

PoorCartonSur$ace

Condition

VacuumSettingtoo low

Vacuum%ine

%eaks

SuctionCupToo Small

SuctionCup

&nadequateMaterial

SuctionCup

'ear No 'ear

No #amage

Could be

(es

(es

Not True

No

No

Could be

&heno$enon

1nce you have e,hausted your Why-Why Cuestionin5(

do the !ause-Effect Relationshis Ma"e Sense and flo)

%ac" to the &heno$enon '

. +o!ical $eie of the Analysis



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*f #e sol,e these causes7 +17 27 ...>$

is it possible that ?34 #ill be reached +;ranch A$:

!A9SE D 7

4ranch :A;

!A9SE D >

!A9SE D B

!A9SE D .

!A9SE D ?

!A9SE D !A9SE D F

!A9SE D




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3epeat the )uestion branch by branch until

the entire analysis has been ,erified.

4RAN!H :A;

Main %ranch :AA;

4RAN!H :!;

4RAN!H :#;

4RAN!H :E;

4RAN!H :3;

4RAN!H :G;

4RAN!H :H;

4RAN!H :4;


; Chec,in! for Standards and SO%9s


42/66

;. Chec,in! for Standards and SO% s

hy

'

W

hy

'

hy

'

hy

'

Why' Std*+

s

Standards.M+s/

h

u

an

e

0ui

ethod

aterial

S1&

i

1

N1

22

2

A

lied'

3

i

el

d

!

h

e

c

"

Y

N

Y

N Restore

Ne)

Std*

Ne)Maint*Std*

YN

WHY-WHY

Before ta,in! counter "easures* chec, to see if standards for the

defined counter "easure e8ist.

If not* define the standard. 4eter"in! if an SO% is needed.

#se the 39s to

ensure all reuiredtypes of standards

e8ist.


43/66

Analysis Stes

5. #nderstandin! the %ro)le"


7. Esta)lishin! Cause-Effect $elationship

throu!h Why uestionin! and 'ield Chec,s.

. +o!ical $eie of the Analysis;. Chec,in! for Standards and SO%9s


44/66

(otes and Adice:

The analysis should )e done at the pro)le" area*

not in another location that is isolated fro" the case.

The analysis is a tea" effort* not )y ust one person.

The "ost i"portant thin! is the physical and&or

lo!ical description of the pheno"enon to )e studied.

@Step 5

The Analysis ends hen counter"easures TOAVOI4 $EC#$$E(CE of the pheno"enon are

found.


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A@&A9/ !a'e a s'etch or dra#ing of thepheno!enon.

The "0Ms dont al#ays apply to e,ery cause to

be analyed7 but #e should al#ays considerthe! so as not to forget possible causes ofcauses.

The !ore si!plicity and obBecti,ity in steps 1

and 27 the easier it is to ensure that all possiblecauses are co,ered.

%ractice de,elops s'ill.

This tool !a'es us !ore obBecti,e in our #ayof loo'ing at things.

5otes and Ad,ice-


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Why&Why - (OT

%ro)le" Why Why Why Why Why Action %lan

Already had the anser*

used the tool to >docu"ent? it

Brainstor"in!*

in a roo"*

no erification


47/66

Real WHY-WHY Analysis E,a$le

Problem)Through put o$ the line *+ is below ideal,

Phenomena)Carton not Picked o$$ the suppl- stack,

.esult) This causes a loss in through put, /Missing Carton0

MissingCarton


48/66

hy

'

7

Missing

Carton

PullingForce

NotStrongEnough

ForcesHoldingCarton

toohigh

Why' 7

Why' >

Seal


49/66

Why' 7

Missing

Carton

PullingForce

NotStrongEnough

ForcesHoldingCarton

toohigh

Why' > SealbetweenSuction

Cup andCarton

inadequate

VacuumForceNot

HighEnough


HoldingFingers

Miss!d"usted

HoldingFrame

TooTight

Why' 7

Why' >

Seal Why' B


50/66

Why' 7

Missing

Carton

PullingForce

NotStrongEnough

ForcesHoldingCarton

toohigh

Why' > SealbetweenSuction

Cup andCarton

inadequate

VacuumForceNot

HighEnough


HoldingFingers

Miss

!d"usted

HoldingFrame

TooTight

SuctionCup

'ear

Why' B

SuctionCup

#amage

PoorCartonSur$ace

Condition


Vacuum%ine

%eaks

SuctionCup

Too Small

SuctionCup

&nadequateMaterial

%ooseCartonStack

Flaps$olded

1ackward

Why' 7

Why' >

Why' .

Why' B


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Why' 7

Missing

Carton

PullingForceNot

StrongEnough

ForcesHoldingCarton

toohigh

Why' >Seal

betweenSuction

Cup andCarton

inadequate

VacuumForceNot

HighEnough

CartonsSticking

To Eachther

HoldingFingers

Miss!d"usted

Holding

FrameTooTight

Why' .

#uston

Carton

Scratcheson carton

Sur$aceFinish

outsidetolerance

Why' B

SuctionCup

#amage

PoorCartonSur$ace

Condition


Vacuum%ine

%eaks

SuctionCup

Too Small

SuctionCup

&nadequateMaterial

SuctionCup

'ear

%ooseCartonStack

Flaps$olded

1ackward

Why' 7

Why' >

Why' .

Why' B


52/66

Why' 7

Missing

Carton

PullingForceNot

StrongEnough

ForcesHoldingCarton

toohigh

Why' >Seal

betweenSuction

Cup andCarton

inadequate

VacuumForceNot

HighEnough

CartonsSticking

To Eachther

HoldingFingers

Miss!d"usted

Holding

FrameTooTight

Why' .

#uston

Carton

Scratcheson carton

Sur$aceFinish

outsidetolerance

Why' B

SuctionCup

#amage

PoorCartonSur$ace

Condition


Vacuum%ine

%eaks

SuctionCup

Too Small

SuctionCup

&nadequateMaterial

SuctionCup

'ear Not worn

Not #amaged

Could be

No #ust

Not true

Problem

Found to be lo

Some %eaks

Correct Si2e


53/66

y

WHY-WHY

lhy

'

Why

'

hy

'

hy

'

Why' Std*+s S1&

i

A

lied'

3

ie

l

d

!

he

c

"

#uston

Carton

Scratcheson carton

Sur$aceFinish

outside

tolerance

SuctionCup

#amage


Vacuum%ine

%eaks

SuctionCup

Too Small

SuctionCup

&nadequateMaterial

SuctionCup'ear

Ntrue

Ntrue

True

True

True

NTrue

(

(

N

Standards.M+s/

hu

an

e0ui

ethod

aterial

3

3

3

33

3

3

N

N

Alied'

Train

#e4elopStds

((

#e4elop SP

Train


54/66

Another exa!ple-

General &ro%le$6

3ive &ort alve

Air cylinder

Air iston $ovin5 too slo)

in %oth directions


55/66

4ra the pro)le"

G t d t di f th


56/66

Get an understandin5 of the rocess6

#ra)in5( &arts

E,haust

3ive &ort alve

Adusta%le

Restrictor

Air cylinder

4otto$seal

Rod seal

4ush

&ies &8

G t d t di f th


57/66


#ra)in5( &arts( &rocess

E,haust

3ive &ort alve

Adusta%le

Restrictor

Air cylinder

4otto$seal

Rod seal

4ush

&ies &8

G t d t di f th


58/66


#ra)in5( &arts( &rocess( 3orces( !ounterforces

E,haust

3ive&ortalve

Adusta%le

Restrictor

Air cylinder

4otto$seal

Rod seal

4ush

&ies &8

Forces

Counter$orces

C d t Wh &Wh


59/66

7* &iston slo)

$ovin5 in 4oth

directions

&heno$ena 7* Why >* Why .* Why ?* WhyB* Why

Conduct Why&Why

C d t Wh &Wh


60/66

7* &iston slo)

$ovin5 in %oth

directions

#efect 7* Why

7* 7 3orce ressure/

too lo)

7* > !ounterforce

too hi5h

>* Why .* Why ?* WhyB* Why

3ield

Aerification

Not True

True

Conduct Why&Why

Cond ct Wh &Wh


61/66

#efect 7* Why

7* 7 3orce ressure/

too lo)

7* > !ounterforce

too hi5h

>* Why

7*7*7 ressure 8

too lo)

7*7*. adusta%le

restrictor closed

7*7*> ? ort valve

defect

.* Why ?* WhyB* Why

7*7*B %loc"ed ie

7*7*? air lea"a5e

3ield

Aerification

Not True

True

Not True

Not True

Not True

7* &iston slo)

$ovin5 in %oth

directions

Conduct Why&Why

Conduct Why&Why


62/66

#efect 7* Why

7* 7 3orce ressure/

too lo)

7* > !ounterforce

too hi5h

>* Why

7*7*7 ressure 8

too lo)

7*7*. adusta%le

restrictor closed

7*7*> ? ort valve

defect

.* WhyB* Why

7*7*B %loc"ed ie

7*7*? air lea"a5e

7* &iston slo)

$ovin5 in %oth

directions

7*7*7*7 not adusted

after cJo to

sha$oo

7*7*7*> Air lea"a5e

3ield

Aerification

True

Not True

Conduct Why&Why

Conduct Why&Why


63/66

#efect 7* Why

7* 7 3orce

ressure/

too lo)

7* > !ounterforce

too hi5h

>* Why

7*7*7 ressure 8

too lo)

7*7*. adusta%le

restrictor closed

7*7*> ? ort valve

defect

.* WhyB* Why

7*7*B %loc"ed ie

7*7*? air lea"a5e

7* &iston slo)

$ovin5 in %oth

directions

7*7*7*7 not adustedafter cJo to

sha$oo

7*7*7*> Air lea"a5e

7*7*7*7*7 No &rocedure

7*7*7*7*> Lac" of

no)led5e

3ield

Aerificatio

n

True

True

Conduct Why&Why

Conduct Why&Why


64/66

.* WhyB* Why

7*7*7*7 not adusted

after cJo to

sha$oo

7*7*7*> Air lea"a5e

7*7*7*7*7 No &rocedure

7*7*7*7*> Lac" of

no)led5e

ossi%le !ounter$easures

- #evelo &rocedure

- Retrainin5( 1&L(s etc(

- isual controls to $a"e easier

to see if off***

Conduct Why&Why


65/66

Case StudyWhy-Why Analysis

&ro%le$ #escrition &ro%le$ &icture &heno$enon

Co"pany A is located on the 7Dth floor of a

hi!h-rise )uildin!. Custo"ers often co"plain

that eleators are slo in co"in!* and there is

a fear that it "ay hae an aderse effect on the

co"panys sales perfor"ance.

A study reealed that "ore isitors co"e to the

co"pany )eteen 57:DD and 5;:DD hours and

that their aitin! ti"e aera!es around 7D sec.

%lease sole this pro)le" )y applin! hy-hy

analysis

&ro%le$ State$ent What does success loo" li"e'

&heno$enon Why -7/ Why ->/ Why -B/ Why -./ Why -?/ !ounter$easures

Have you verified the cause'


66/66

WHY - WHY ANALYSIS

$EVIEW VS. OBJECTIVES: #nderstand the definition of >Analysis?

Clarify the procedure for deelopin! a Why - Why

Analysis.

Stress the i"portance of each step of the Why - WhyAnalysis.

@*M*5AT*45

4( @4///

THE

EN#

7217166 Why Why Analysis

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