2013 Manufacturing Principles

<<DRAFT>>
5 Whys
Question the problem

Why?
Why?
Why?
Why?
Why? (5 Times, maybe more or less)

Breaks problem down to root cause

The final Why is not a person or object. It should be actionable.
Use data to drive decisions
Example of 5 Whys
5 Why Analysis
Missing Parts at Pack Line

Problem | Why #1 | Why #2 | Why #3 | Why #4 | Why #5

Pack operator fails to
Hardware pack missing
place hardware pack in
from grill carton
carton
Pack operator loses Conveyor line moves No sensors are in place Poka-yoke devices were
count of boxes on continuously without to stop line if work is not considered when
conveyor line stopping for work not complete designing pack line

Pack operator turns Hardware pack No provision to stage

away from line to pick container is located hardware in front of
up hardware pack behind operator at line operator at line

Pack operator fails to
Side burner trivet
place side burner trivet
missing from grill carton
pack in carton
Pack operator loses Conveyor line moves No sensors are in place Poka-yoke devices were
count of boxes on continuously without to stop line if work is not considered when
conveyor line stopping for work not complete designing pack line

Pack operator turns Side burner trivet No provision to stage

away from line to pick container is located trivet in front of operator
up trivet behind operator at line at line

Pack operator fails to
Cooking grid is missing
place cooking grid in
from grill carton
carton
Pack operator loses Conveyor line moves No sensors are in place Poka-yoke devices were
count of boxes on continuously without to stop line if work is not considered when
conveyor line stopping for work not complete designing pack line

Pack operator turns Cooking grid container No provision to stage

(Reduced example
away from line to pick is located behind cooking grid in front of
for training!)
up cooking grid operator at line operator at line