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10 rules of “Whys Analysis”

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(1) State succinctly

State succinctly, and with a subject.

（ Case ）

× The battery is dead, and the flashlight does not work.

correct State with a subject.

△
why
The flashlight does not work. The battery is dead.

correct Consider other causes.

why
○ The flashlight does not work. The battery is dead.

The buttery is not in contact with the spring.

The bulb has gone.

Notice ： Do not forget the “4W1H” because of being so simple.

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(2) State with simple words that anyone can understand

Do not use ambiguous phrases
（ Case ）
　　　 Ambiguous phrases: “○○ is bad” 　 State with simple words

×
correct
Material is bad Material has a bad thickness.

Material has a bed tensile strength.

no a subject 　　　　　　　　　　　　　　 State the defective object.

×
correct
The ○○ part of the ○○ product
Transformed is transformed.
　　

　　An ambiguous phrase is likely to cause different meanings, and to cause a

wrong analysis.
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(3) Specify comparison object

Specify the comparison object when you compare matters.

（ Case ）
　　

×
correct The diameter of the bolt is larger than
The diameter of the bolt is too
large. that of the hole.

The diameter of the hole is smaller

than that of the bolt.

　　　

×
The time a product takes to correct The time a product takes to pass the
pass the detection part of the detection part of the device is shorter
device is short. than the sensor takes to detect.

The time the sensor takes to detect is

longer than a product takes to pass
the detection part of the device.
　　　　
Probably the comparison object has problems.
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(4) Take conditions into consideration and then start

How to narrow down factors will affect how to start.
And when you could not completely narrow them down, you’d better try taking
conditions into your consideration.
（ Case ） There are several conditions for producing products.
　　　 → If one of them changed, defective products are produced.
Then you should fundamentally revise the changed condition.

A complaint case about “missing parts”

【 Nondefective Conditions 】
Conditions to provide nondefectives to customers:
　・ Fix parts correctly by rules.
　・ Parts do not break away during following process or in transit.
【 Whys 】
whys
A product having no a part
The part was forgotten to fix.
was found.

The fixed part broke away.

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(5) Confirm correctness logically

…come back to causes from events
From events, confirm whether causes are correct and whether there are not
gaps in the logic.
（ Case ）
why
The car banged a guardrail. Road was icy.
　
Let’s confirm whether the cause is correct.
　 　“ The road was icy”, so “the car banged the guardrail”.
　　　　　　　　　　　　　　　　　　　　　　　　　 (There’s a gap in the logic.)
　 → Correction: The road was icy, so the car slipped,
　　 and banged the guardrail.
correct
why1 why2
The car banged a
The car slipped. Road was icy.
guardrail.
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(5) Confirm correctness logically

…come back to causes from events －Ⅱ
From events, confirm whether causes are correct and whether there are not
gaps in the logic.
（ Actual case) Taking wrong parts up
why2
why1 why3
Both of the parts
The operator only The plate printed
placing spaces were
checked color and shelf numbers was
adjoining, and
Different parts got shape of parts, but the same color and
colors and shapes
mixed up didn’t check the shape as the plate
were similar to each
plate printed shelf printed numbers of
other.
numbers.

×
products. And the
operator would have

×
checked the plates.

We could not come to the causes from the event.

・ The “why2” was only an explanation of the then state.
・ The “why1” said “the operator only checked color and
shape, but didn’t check the plate”, but “why3” said “the
operator would have check the plate”, that was inconsistent.
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(6) Take up causes having parallel relation without missing

Confirm whether this failure was for this cause.
（ Case ）
why
The flashlight does not work. The battery is dead.

why
The flashlight does not work. The battery is dead.

The battery is not in contact with the spring.

The bulb has gone.

Take up all causes what you can think out.

　　　・・・ And verify them with facts.
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(7) Verify causes with actual objects at the scene

　　　 Narrow down causes by verifying facts

To “whys”,
You should watch the actual objects at the scene well,
and interview and confirm records and take reproduction test.
And then you should verify causes from the facts above.

When you narrow causes, you should take away the causes which
have been considered impossible.

You should surely verify causes with actual objects at the scene
but are not in your thoughts.
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(8) Warn the causes which don’t making sense

Even if the causes are reasonable, do not take up them in a normal condition.
Take up the causes which are away from a normal condition and might be abnormalities.

（ Case ）

why1 why2
Dust in the cleanroom
is over the standard

×
Machines Machines operating
gathered dust. time increased. ＊

why3 why4

× ×
＊ Production increased. Orders increased.

It is important to analyze causes with the measures in mind.

　 (In the case above, how to make source of dust clear is important)
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(9) Do not analyze the causes due to one’s heart

Do not analyze these causes, such as “He was in a daze.” or “He was careless.”
→ You should try to investigate machines or management system but not one’s
heart.
( Actual case) Incorrect incoming sheet
why1 why2

The operator put He didn’t check the He thought that

an incorrect goods name on the it was so.
incoming sheet on sheet.
the product box.

He didn’t check the There was not a

goods name on the rule to check.
sheet.
　　　　
Do not try to pay attention to one’s heart like “He was in a daze,” “He was
careless,” or “He thought…”, 　 ・・・　 Because you cannot help him.

　You should investigate the causes due to systems such as management,

operation or machine, and think how to take measures against them.
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(10) Continue the “whys” until you had have prevention measures
Look into the causes until you have found the factors to prevent occurrence.
（ Case ）
why1 why2 why3 measures
○○ section

×
The event Clean ○○ section.
wasn’t cleaned.

（ correction ）

why3 why4 why5 measures

There wasn’t rules Create rules for
○○ section
about cleaning ○○ cleaning ○○ section.
wasn’t cleaned.
section.
It took time to
It was hard to clean Convert the cover on
remove the cover on
○○ section. the ○○ section to
the ○○ section.
　　　　　　 automatic.
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10 rules about “whys analysis” Summary

10 rules Notes

1 State succinctly. A sentence has a subject.

State with simple words that anyone can

2 Don’t use ambiguous phrases.
understand.

3 Specify comparison object. Pay attention to comparison object.

That is especially important when you

4 Take conditions into consideration.
couldn’t gather all facts.
Confirm whether you can come back to
5 Confirm correctness logically. 　
causes from events.
Take up causes having parallel relation without Confirm whether this failure was for this
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missing. cause.

7 Verify causes with actual objects at the scene. Confirm facts.

8 Warn the causes which don’t making sense. Keep prevention measures in mind.

9 Don’t analyze the causes due to one’s heart Look into systems.

Continue the “whys” until having prevention Look into the causes until you have found
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measures. the factors to prevent occurrence.