5 Why Training Slides Oct 14, 2009

5 Why Training Slides Oct 14, 2009

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  5 Why TrainingIntroductionto SystematicProblem Solving
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  Code of ConductArrive to Training on Time and Keep to Time Schedule
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  Listen toEveryone's Opinion with Respect
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  Keep anOpen Mind
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  Respect andSupport Team Roles
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  Stay inthe Meeting while Others are Talking
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  Turn OffMobile Phones (Put on Silent as a Minimum)
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  Have Fun!AgendaINSTRUCTOR: John F. Petak7:00 am - 7:30 am Introductions / Review the Current Situation7:30 am - 8:00 am Introduction to TOPS 8D8 :00 am - 8:20 am Individual Exercise - “ Puzzle ”8:20 am - 8:50 am Defining Problems8:50 am - 9:00 am Break9:00 am - 9:30 am Introduction to 5 Why’s 9:30 am - 10:10 am Team Exercise – “ Albatross ”10:10 am - 10:50 am Team Exercise – “The Real World”10:50 am - 11:00 am Wrap Up / Feedback
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  Father of JustIn Time ManufacturingDo you know his name?
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  “If you don’task the right questions, you don’t get the right answers. A question asked in the right way often points to its own answer. Asking questions is the ABC of diagnosis. Only the inquiring mind solves problems. “Why?6
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  7The PUZZLE Exercise
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  What is aProblem?According to WEBSTERS Dictionary:A Problem is a difficult or perplexing question or issue; a question posed for consideration, discussion or solution.In Lean Manufacturing:A Problem is a gap between the current condition (what is) and the desired condition (what should be) and the CAUSE for the gap is unknown.8
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  What is aCause?According to WEBSTERS Dictionary:A Cause is a reason for an action or condition; something that brings about an effect or resultIn Lean Manufacturing:A Cause is a factor that immediately precedes the problem and always produces it. For a factor to be a Cause, it must also be capable of producing the problem by itself9
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  Why 5 Whys?Byrepeatedly asking the question “Why?”, you can peel away the layers of symptoms and identify the Root Cause of the problem.
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  A RootCause is an Identified Reason or Source for the presence of a Defect or Problem
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  Once aRoot Cause is identified and corrected, prevention of the recurrence is possible.10
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  Benefit of 5WhysPoints to the Root Cause of the Problem
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  Highlights the relationshipbetween several potential Root Causes of a Problem
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  Allows for rapidproblems solving without the use of Statistical ToolszzZZ?zzZZ?zzZZ?zzZZ?zzZZ?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?WHY?11
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  The 5 WhyProcessWrite Down the Specific Problem- Helps you define it completely- Focuses the team on the same problemAsk WHY the Problem happened and write down the AnswerIf the Answer is not the Root Cause, Ask WHY the Answer happened and write down the new AnswerRepeat Step 3 until the team agrees that the Root Cause has been identified. - May take more or less than 5 Whys- Keep asking until you can no longer answer12
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  13Albatross Exercise
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  14Albatross Exercise Solution
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  5 Why ExamplePROBLEMSTATEMENT: MY CAR STOPPED WORKING ON THE WAY TO WORK 1. WHY DID YOUR CAR STOP WORKING?BECAUSE IT RAN OUT OF GAS2. WHY DID YOUR CAR RUN OUT OF GAS?BECAUSE I DIDN’T BUY ANY GAS THIS MORNING3. WHY DIDN’T YOU BUY ANY GAS THIS MORNING?BECAUSE I DIDN’T HAVE ANY MONEYBECAUSE I LOST IT ALL LAST NIGHT IN A POKER GAME4. WHY DIDN’T YOU HAVE ANY MONEY?5. WHY DID YOU LOSE ALL YOUR MONEY IN A POKER GAME LAST NIGHT?BECAUSE I AM NOT GOOD AT BLUFFING WHEN DON’T HAVE A GOOD HANDSOLUTION: QUIT PLAYING POKER OR LEARN HOW TO BLUFF… 15
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  5 Why ExamplePROBLEMSTATEMENT: Pizza Delivered Cold1. Why was the pizza cold?It sat in the bag too long2. Why was it in the bag too long?The driver got lost3. Why did the driver get lost?He did not know the directionsHe did not have a map 4. Why did he not know the directions?5. Why did he not have a mapThe Pizza company ran out of themSOLUTION: Buy more maps and issue them to all drivers16
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  17Flying Horses?
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  18Always Question Data
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  How Does Trust-MentorCurrently Solve Problems? 19
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  Roadblocks to EffectiveProblem Solving Problem described incorrectly
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  Problem Solvingeffort rushed through
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  Poor TeamParticipation
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  Lack ofTechnical Knowledge
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  Poor ManagementSupport
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  Potential Causedmisidentified as the Root Cause
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  Corrective Actionnot implemented 20
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  Problem Influences MANPOWER
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  MATERIAL
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  MACHINE
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  METHODS
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  MEASUREMENT OTHERINFLUENCES CAN BE: MANAGEMENT (POLICES)
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  MONEY
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  ENVIRONMENTALThe 5Ms21
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  The 5 WhyProcessBenefits: Easy to learn and Easy to use
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  A systematicapproach
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  Challenges assumptions
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  Non-blaming andNon-judgmental
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  A teamapproachWeaknesses:Tendency to stop short of true root cause
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  Limited tocurrent knowledge
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  Results arenot always repeatable22
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  235 Why -Real World Exercise