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Over time, continuous incremental investments and improvements will compound, improving the productivity of maintenance personnel and freeing up time that was previously lost fire-fighting breakdowns.In the context of maintenance, the 5 whys framework offers a simple problem-solving technique for getting to the heart of an issue and determining long-term corrective actions that should be taken.
Having to address a problem or failure mode more than once is time consuming and a waste of valuable resources.
The issue is that the root cause is not being identified or addressed. Toyoda is the founder of Toyota Industries and is said to be one of the fathers of Japan’s industrial revolution.
In Six Sigma, the “define, measure, analyze, improve, and control” (or DMAIC) method aims to use statistical analysis to implement process improvement wherever it’s needed.
Root cause analyses are typically carried out by a cross-functional team so the problem can truly be understood from as many viewpoints as possible. Since the root of a problem is usually multi-faceted and occurs somewhere beneath the obvious problem at hand, this method aims to ask, “Why did this occur?
There is a simple to use tool that can help eliminate repeat problems. The 5 Why method is often used during the Analyze phase of the DMAIC process and the Plan phase of PDCA activities.
It is often used in coordination with other analysis tools such as the Cause and Effect Diagram but can also be used as a standalone tool.
There were likely many little things that contributed to the failure.
If you want to prevent the problem from occurring again, you have to dig deeper and look at it from all sides.
You need to figure out the root cause in order to fix the underlying issue.
Using the “5 whys” method, we start by asking why: If we just replaced the damaged fan, the issue would recur. ” while the root cause still has a connection to the original problem.