Template for Brainstorm and 5 Whys

Extract of SQF-QA-82-00079 (Rev.B)

4.a Brainstorm Ideas
 
 
MAN METHOD MATERIAL

Inadequate CATIA knowledge Wrong 3D ply definition Unexpected material

of new designers (interns) shrinkage
Wrong 2D ply definition
Unskilled operators not meeting
lay-up tolerance requirements

Effect

Flange
thickness
variation
out of
Wrong Lectra cut or program Mix-up between EEOP and No probable causes
tolerance
MEOP

Unanticipated functionality
change due to CATIA Version
upgrade

Grit strip location

LM tool surface

MACHINE MEASUREMENT ENVIRONMENT

Use the above Ishikawa (fish bone) diagram 4a to brainstorm the problem. Use consensus voting to select the three
most probable causes to transfer into table 4 and conduct the 5 Why’s analysis to determine root cause.
The standard categories of HUMAN, MACHINE, METHOD and MATERIAL may be used or any others that are relevant
to the problem.

We select the following reasons to be most significant:

Wrong 2D ply definition in CATIA for Lectra ply cutter resulted in too short plies at the critical
locations.

Inadequate CATIA knowledge of new designers (interns)

STRATA MANUFACTURING PJSC– PO BOX 86519, AL AIN – UNITED ARAB EMIRATES

 Template for Brainstorm and 5 Whys
Extract of SQF-QA-82-00079 (Rev.B)

4.b Diagnostics
 
Why does the problem exist? – Ask Why?

Select the most prominent/probable causes, ask why each occurs and record the answer in the box below. For the
answer you have just recorded ask why again and put the answer in the box below. Continue to do this until you have
exhausted the question why. Some may not require all 5 Y’s, but ensure that the 5 Y’s have been exhausted before
moving to section 5. To the contrary some causes may take more than 5 Y’s, use as many Y’s as required to get down
to the root cause (if more than 5 Y’s are required insert more rows into this document).

When this task is complete, it gives you the root cause/causes. Use table 5 to implement corrective actions to prevent
the failure from occurring again.
 
Brief description Probable Cause 1 Probable Cause 2 Probable Cause 3
of cause

Why 1 Wrong 2D ply definition in Inadequate CATIA

CATIA for Lectra ply cutter knowledge of new designers
(interns)

Why 2 No verification of the No formal procedure exists

flattened geometry is for training of new personnel
performed against the in the Design Team.
required 3D-boundaries.

Why 3 Inadequate process of

ply flat pattern creation
from the 3D-model

Why 4 Current process of 2D

ply definition has been
based on a presentation
without formal QMS
procedure

Why 5

Action:

1. Create an SQI for design engineers to be guided by when working on 2D ply

definition (flattening). The instruction shall include a verification process, which will
ensure alignment between the original 3D and the outcome 2D ply boundaries.
2. Conduct an internal training for the current design team staff when the new procedure
is released.

STRATA MANUFACTURING PJSC– PO BOX 86519, AL AIN – UNITED ARAB EMIRATES