𝗪𝗵𝘆? 𝘅𝟱

The five why analysis is more than just asking a series of questions beginning with “why”, each one of them must lead to the next, and ultimately to the root cause of the problem. If you strive for perfection then it's critical to find and remove even the smallest of discrepancies or problems in your operation. Once you discover an issue, by repeatedly asking the question “why?”, you can peel away the layers of symptoms that can lead to the underlying root of the problem.

In nearly any situation, very often the ostensible reason for a problem will lead you to another question. The ‘5 Why’ method of solving such a conundrum is part of the Toyota Production System. Developed by Sakichi Toyoda, a Japanese inventor, and industrialist, the technique became an integral part of the lean philosophy and is as applicable today as it was when penned.

One of the key factors for the successful implementation of the technique is the ability of the user to make an informed decision. This means that the decision-making process should be based on an insightful understanding of what is actually happening on the factory floor; something which leads back to the principle of two-way feedback spanning staff at every level that we have discussed previously.

Once you have gathered the correct team of employees to conduct the exercise, applying the method couldn’t be simpler:

1/ Write down the specific problem.

2/ Ask Why the problem happens and write the answer down below the problem.

If the answer you just provided doesn’t identify the root cause of the problem that you wrote down in step 1, ask Why again and write that answer down. Repeat the above until it is certain the problem’s root cause is identified. This may take fewer or more times than five Whys. Operating in such a clear methodical way creates an understanding of the expectation in solving issues, and works quickly to determine what needs to be done to maintain a flawless manufacturing process.

Utilizing such practice are ADIS Tachov s.r.o.. As experts in the production of auto plastics, they are abundantly aware of the need to resolve even the tiniest of issues quickly and effectively, and the 5-whys is just one example of how they achieve this to a world-class standard.