The Why-Why Analysis

Original: Feb ’06; Rev 00.0 (Feb ’06)

Five Key Points for a Successful Analysis

Kiran Deshmukh | Sona Koyo Steering Systems Ltd

Why-Why Analysis

• Simplest of all analyses.

• Does not require mathematical knowledge.
• Closest to the reality.
• Drives to the “real” root cause.
Simple Method; Simple Format!

Problem:

Why Answer Action

Simple things are generally the most difficult!

The Five Keys for a Successful Why-Why
Analysis
1. Apply for sporadic loss.
2. Begin with the action taken for fixing the loss
temporarily.
3. Go back each step to check that the causes
are arrived at logically.
4. The final answer must result in a change in
the standard.
5. Must be done TODAY for analyzing
TODAY’S problem.
1. Root Cause of Every Sporadic Problem Can Be
Found Out Through Why-Why Analysis.

2.5

2.0
Sporadic case
Rejection, pct

1.5

Why-why analysis should not be

1.0 applied for chronic problems.

0.5

0.0
1

13

15

17

19

21

25
11

23
Day
Sporadic loss is when an entirely new phenomenon suddenly
occurs after exceeding a certain dispersion range.
The Problem to Tackle Must Be ‘Sporadic’

Problem: Cylinder does not operate smoothly.

Why Answer Action

Sporadic
problem
2. Start Why-Why Analysis With the Action
Taken to Fix the Problem.
• Sporadic losses can be solved on the spot.
• Restorative measures will work in most
sporadic cases.
• This restorative action should be the first step
in any why-why analysis.

“Did you do adjustment?”  Yes!

“Did the problem get solved after the adjustment?”  Yes!

The first action in the why-why analysis: <the

adjustment>
The First Action: Action Taken to Fix the
Problem

Problem: Cylinder does not operate smoothly.

Why Answer Action

Why is operation not Strainer clogged. Clean strainer.
smooth?

Action taken
to fix the
problem
Go Down the Causes in a Logical Manner

Problem: Cylinder does not operate smoothly.

Why Answer Action

Why is operation not Strainer clogged. Clean strainer.
smooth?
Why has strainer Oil was dirty. Drain oil and clean.
clogged?
Go Down the Causes in a Logical Manner

Problem: Cylinder does not operate smoothly.

Why Answer Action

Why is operation not Strainer clogged. Clean strainer.
smooth?
Why has strainer Oil was dirty. Drain oil and clean.
clogged?
Why did oil get dirty? Dirt entered tank. Prevent scattering of
chips and cutting fluid.
Go Down the Causes in a Logical Manner

Problem: Cylinder does not operate smoothly.

Why Answer Action

Why is operation not Strainer clogged. Clean strainer.
smooth?
Why has strainer Oil was dirty. Drain oil and clean.
clogged?
Why did oil get dirty? Dirt entered tank. Prevent scattering of
chips and cutting fluid.
Why did dirt get in? Upper plate of tank Plug hole and gap.
has a hole and gap.
3. Go Back Up to Check the Logic

Problem: Cylinder does not operate smoothly.

What would have

If … not, then …
happened?
Why is operation not smooth? Strainer clogged.

Strainer would not have clogged. If oil was not dirty, then…

Oil would not get dirty. If dirt did not enter tank, then…

Dirt would not get in. If upper plate of tank did not have
a hole and gap, then…
The Biggest Mistake in Why-why Analysis:
Not Going to the Root Cause

Problem: Cylinder does not operate smoothly.

Why Answer Action

Why is operation not Strainer clogged. Clean strainer.
smooth?
Why has strainer Oil was dirty. Drain oil and clean.
clogged?
Why did oil get dirty? Dirt entered tank. Prevent scattering of
chips and cutting fluid.
Why did dirt get in? Upper plate of tank Plug hole and gap.
has a hole and gap.
4. Last Step in the Analysis Must Be Related
to Standardization, So Some Human Error

Problem: Cylinder does not operate smoothly.

Why Answer Action

Why is operation not Strainer clogged. Clean strainer.
smooth?
Standardization
Why has strainer Oil was dirty. Drain oil and clean.
clogged?
Why did oil get dirty? Dirt entered tank. Prevent scattering of
chips and cutting fluid.
Human error
Why did dirt get in? Upper plate of tank Plug hole and gap.
has a hole and gap.
Why was hole made? Repair error during Standardize repair.
maintenance work.
Prevention Is Improvement in Standards

Customer Customer
Complaint Complaint

In-house
Rejection
In-house
Rejection

Fix
position by
prevention

Improvement

PREVENTION: Improvement in standards / procedures

Good Why-Why Analysis Results in
Permanent Preventive Countermeasure
• Preventive action is making sure that not only this, but also this
type of problem never recurs.
• This can be achieved by:
– Looking at the human-related root cause:
• Weak design.
• Improper repair.
• Improper inspection.
• Improper operation.
– Changing current standard or making a new one with the aim of
addressing the above human-related issues.

NOTE: Look for internal failures, and correct them through

standardization.
Machine maker’s fault in bad machine design  Our fault in not
inspecting the machine appropriately.
5. Why-Why Analysis Must Be Done on the
Spot (Time and Space)
• Why-why analysis addresses a one-time sporadic
problem.
• Accurate analysis can be done only when the
evidence is in front of the eyes of the person
engaged in analysis.
• Don’t forget the 4G principle:
– Gemba: Go to the site
– Genbutsu: Touch the actual part(s)
– Genri: Think about the principle behind the phenomenon
– Gensoku: Study what should be by applying the principle to
the actual situation
The Five-Point Check Sheet for a Good Why-
Why Analysis

Problem:

Why Answer Action

1. Is this a
sporadic
problem?
2. Did this action result in—
even if temporarily—fixing the
problem?

3. Can you go back

applying <“if not 4. Check: Answer:
5. Done on the
then… this would not Internal human error;
spot <time and
happen”> logic? Action: standardization.
space>?
Example of Why-Why Analysis: Can You
Apply the Five Point Check Sheet?

Problem: Oil leaks from cylinder rod each time it

operates.
Why Answer Action
Why did it leak? Cut in O-ring. Replace O-ring.
Why was it cut? Rod has a scratch. Remove scratch.
Why was it scratched? Chips were scattered and Take measures to prevent
attached on the rod. chips from scattering.

Why did chips get Cylinder is located within Change cylinder position.
attached? scattering range of chips.
Rod cover is not placed. Install cover.
Why is rod placed in that Defective design and Standardize design and
position? installation. installation.
Why no cover?
End of the Presentation

© 2006, Sona Koyo Steering Systems Ltd