5 why training slides oct 14, 2009

Sky Miltronics/Trust TechnologiesAugust 2009

5 WHY TRAINING

Introduction to Systematic

Problem Solving


Code of Conduct Arrive to Training on Time and Keep to Time

Schedule

Listen to Everyone's Opinion with Respect

Keep an Open Mind

Respect and Support Team Roles

Stay in the Meeting while Others are Talking

Turn Off Mobile Phones (Put on Silent as a Minimum)

Have Fun!


INSTRUCTOR: John F. Petak7:00 am - 7:30 am Introductions / Review the Current Situation

7:30 am - 8:00 am Introduction to TOPS 8D

8 :00 am - 8:20 am Individual Exercise - “ Puzzle ”

8:20 am - 8:50 am Defining Problems

8:50 am - 9:00 am Break

9:00 am - 9:30 am Introduction to 5 Why’s

9:30 am - 10:10 am Team Exercise – “ Albatross ”

10:10 am - 10:50 am Team Exercise – “The Real World”

10:50 am - 11:00 am Wrap Up / Feedback

Agenda


Father of Just In Time ManufacturingDo you know his name?


“If you don’t ask the right questions, you don’t get the right answers. A question asked in the right way often

points to its own answer. Asking questions is the ABC of diagnosis. Only the inquiring mind solves problems. “

Why?

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Sky Miltronics/Trust TechnologiesAugust 2009 7

The PUZZLE Exercise


According to WEBSTERS Dictionary:

A Problem is a difficult or perplexing question or issue; a question posed for consideration, discussion or solution.

In Lean Manufacturing:

A Problem is a gap between the current condition (what is) and the desired condition (what should be) and the CAUSE for the gap is unknown.

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What is a Problem?


According to WEBSTERS Dictionary:

A Cause is a reason for an action or condition; something that brings about an effect or result

In Lean Manufacturing:

A Cause is a factor that immediately precedes the problem and always produces it. For a factor to be a Cause, it must also be capable of producing the problem by itself

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What is a Cause?


• By repeatedly asking the question “Why?”, you can peel away the layers of symptoms and identify the Root Cause of the problem.

• A Root Cause is an Identified Reason or Source for the presence of a Defect or Problem

• Once a Root Cause is identified and corrected, prevention of the recurrence is possible.

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Why 5 Whys?

Why?

Why?

Why?

Why?

Why?

Root Cause


• Points to the Root Cause of the Problem

• Highlights the relationship between several potential Root Causes of a Problem

• Allows for rapid problems solving without the use of Statistical Tools

zzZZ?zzZZ?zzZZ?zzZZ?zzZZ?

WHY?WHY?WHY?WHY?WHY?



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Benefit of 5 Whys


1. Write Down the Specific Problem- Helps you define it completely- Focuses the team on the same problem

2. Ask WHY the Problem happened and write down the Answer

3. If the Answer is not the Root Cause, Ask WHY the Answer happened and write down the new Answer

4. Repeat Step 3 until the team agrees that the Root Cause has been identified. - May take more or less than 5 Whys- Keep asking until you can no longer answer

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The 5 Why Process


Albatross Exercise


Albatross Exercise Solution


PROBLEM STATEMENT: MY CAR STOPPED WORKING ON THE WAY TO WORK

1. WHY DID YOUR CAR STOP WORKING? BECAUSE IT RAN OUT OF GAS

2. WHY DID YOUR CAR RUN OUT OF GAS?BECAUSE I DIDN’T BUY ANY GAS THIS MORNING

3. WHY DIDN’T YOU BUY ANY GAS THIS MORNING?

BECAUSE I DIDN’T HAVE ANY MONEY

4. WHY DIDN’T YOU HAVE ANY MONEY?BECAUSE I LOST IT ALL LAST NIGHT IN A POKER GAME

5. WHY DID YOU LOSE ALL YOUR MONEY IN A POKER GAME LAST NIGHT?

BECAUSE I AM NOT GOOD AT BLUFFING WHEN DON’T HAVE A GOOD HAND

SOLUTION: QUIT PLAYING POKER OR LEARN HOW TO BLUFF…

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5 Why Example


PROBLEM STATEMENT: Pizza Delivered Cold

1. Why was the pizza cold? It sat in the bag too long

2. Why was it in the bag too long? The driver got lost

3. Why did the driver get lost? He did not know the directions

4. Why did he not know the directions? He did not have a map

5. Why did he not have a map The Pizza company ran out of them

SOLUTION: Buy more maps and issue them to all drivers

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5 Why Example


Flying Horses?


Always Question Data


How Does Trust-Mentor Currently Solve Problems?


• Problem described incorrectly

• Problem Solving effort rushed through

• Poor Team Participation

• Lack of Technical Knowledge

• Poor Management Support

• Potential Caused misidentified as the Root Cause

• Corrective Action not implemented

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Roadblocks to Effective Problem Solving


• MANPOWER• MATERIAL• MACHINE• METHODS• MEASUREMENT

OTHER INFLUENCES CAN BE:

• MANAGEMENT (POLICES)• MONEY• ENVIRONMENTAL

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Problem Influences

The 5 Ms


Benefits:

• Easy to learn and Easy to use• A systematic approach • Challenges assumptions• Non-blaming and Non-judgmental• A team approach

Weaknesses:

• Tendency to stop short of true root cause

• Limited to current knowledge• Results are not always repeatable

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The 5 Why Process


5 Why - Real World Exercise

5 why training slides oct 14, 2009

Documents

time schedule

support team roles

mobile phones

everyones opinion

code of conduct

open mind