How to Conduct 3x5 Why Analysis in the Workplace.pptx

At the end of this training module, you will able to solve the problem using 3x5 Why Analysis.

1. 3 X 5 Why Analysis Training By: Ninia Didulo

2. Training Outline Amkor Confidential 2 The POWER of asking question The type of Question that will mean a lot Back to Basics History and beyond The heart of 5 Why Analysis

3. T ra i ning O bject i ves Amkor Confidential 3 At the end of the course, the participants are expected to: Acquire a clear understanding on the importance and purpose of Why-Why Analysis Learn the techniques how to generate a “customer ready and acceptable” Why-Why Analysis Be able to differentiate the Technical Root cause against Systemic Root Cause Apply the Why-Why Anal y sis e f fecti v ely when there are quality issues in his/her area of responsibility

4. Training Requirement Amkor Confidential 4 S tay focus P articipate A dapt to the changes…. R ead y your “inqui s it i ve M IND” E njoy the training S P A R E!

5. The POWER of asking Question Amkor Confidential 5 W hy are you here today?

6. The POWER of asking Question Amkor Confidential 6 “If you don’t ask 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.” – Edward Hodnett

7. The POWER of asking Question Amkor Confidential 7 What is the right question? When are you going to sleep? or what time are you going to sleep?

8. The POWER of asking Question Who are the best at asking questions? Amkor Confidential 8

9. The POWER of asking Question Amkor Confidential 9 - because they keep asking objective , open-ended questions until the answer is simple and clear

10. The POWER of asking Question Amkor Confidential 10

11. Closed-Ended vs. Open-Ended Questions Amkor Confidential 11 Close-Ended : Structures the response to be answered b y one word , often “ ye s” or “ n o ” . Usua l l y gives a predetermined answer. Example: “Did the lack of standardization cause the incorrect setup?” Open-Ended : Leaves the form of the answer up to the person answering which draws out more thought or research. Example: “How is setup controlled?”

12. Example 1: “Did the lack of a PM system cause this tool to break?” (Close-Ended question, can be answered by a “yes” or “no”, gives The person a predetermined answer that PM is to blame) “What could have caused the tool to break?” (Open-Ended, probing question forces the person to think about all possibilities, not just PM) Closed-Ended vs. Open-Ended Questions Amkor Confidential 12

13. Example 2: “Would improving material flow help reduce lead times?” (Good question but it’s still Close-Ended, focuses the person on material flow as a means to reduce lead time. Is this the best improvement?) “What are some options on improving lead time? (Open-Ended, triggering more thought and research on all variables impacting lead time.) Closed-Ended vs. Open-Ended Questions Amkor Confidential 13

14. Example 3: “Is equipment capability causing the variation in your process? (Close-Ended, can be answered by a “yes” or “no”, focuses the person On equipment being the source of variation) “What could potentially cause variation in your process? (Open-Ended, triggering more thought and research, opens up Possibilities of variation with man, material & method, not just machine) Closed-Ended vs. Open-Ended Questions Amkor Confidential 14

15. Benefits of Open-Ended Questions Amkor Confidential 15 Does not assume there is one right answer Promotes additional research Requires thought ?

16. Benefits of Open-Ended Questions Amkor Confidential 16 Avoids predetermined answers Enhances problem solving skills Stimulates discussion

17. Benefits of Open-Ended Questions Amkor Confidential 17 In many circumstances, it is not only the answer itself, but the process by which the answer was determined that is important when asking an Open-Ended question Empowers the person answering

18. Fundamentals of Problem Solving Amkor Confidential 18 The word “failure” is abstract . Each defect of a product or service is a failure. You can only eliminate failures in case you know the root cause . Root Cause is. . . A process factor which directly defines the reason for the problem (failure) when it is present and is having an influence on the process and its output.

19. Fundamentals of Problem Solving Initial problem feedback Identify/ Clarify the problem Team Brainstorming for Potential Root Causes Test the Hypothesis Zoom In Decide on the Point of cause Cause A nal y sis using 3x5 HY Analysis Grasp the Situation, un d e r st a ndi n g t h e problem Tools: Hypothesis Table IS / IS NOT Table Cause & Effect or ( I sh i ka w a / Fishb on e) Fault Tree Etc… W h y ? W h y ? W h y ? A m k o r C on fi den ti a l 21

20. A m k o r C on fi den ti a l 22 Fundamentals of Problem Solving – Understanding the problem U n it Anal y s is Lot to Lot Commonality 4M History / Events Is – Is Not Analysis

21. Fundamentals of Problem Solving – RCA Tools Amkor Confidential 21

22. The 5 WH Y s… Amkor Confidential 22 Method was developed by Sakichi Toyoda Was incorporated to the Toyota Production System (architect by Taichi Ohno) as a critical component of problem solving training Objective: reach the real root cause Ask several times the question Why until you hit the real root cause

23. Sample Why-why Analysis: Amkor Confidential 23 Why1."Why did the robot stop?" The circuit has overloaded, causing a fuse to blow. Why2. "Why is the circuit overloaded?" There was insufficient lubrication on the bearings, so they locked up. Why3. "Why was there insufficient lubrication on the bearings?" The oil pump on the robot is not circulating sufficient oil. Why4. "Why is the pump not circulating sufficient oil?" The pump intake is clogged with metal shavings. Why5. "Why is the intake clogged with metal shavings?" There is no filter on the pump.

24. 3X5 WHY Solution Pattern Method: The problem solver simply asks a Why-question approximately five times in series in 3 dimensions: Amkor Confidential 24 PR E VENT PROTECT P R E DICT 1 The Occurrence (non conformity ) Why do we have the problem? 2 The Escape (non detection ) Why did we not detect the problem? The System (predictive/preventive) Why did the system allow this problem to happen? 3

25. Technical Root Cause vs System Root Cause Amkor Confidential 25 Each failure has a Technical Root Cause (TRC) that is directly related to the symptom. Some failures can have more technical causes. Failures occur not intentionally but they occur systematically . That means that behind the TRC there is a (Managerial) Systemic Root Cause (SRC), that allows the TRC to happen

26. Technical Root Cause vs System Root Cause Amkor Confidential 26

27. Technical Root Cause vs System Root Cause Amkor Confidential 27

28. Basic 5-Why Solution Pattern Amkor Confidential 28 The 5-Why method of root cause analysis requires you to question how the sequential causes of a failure event arose and identify the cause-effect failure path. ‘Why’ is asked to find each preceding trigger until we supposedly arrive at the root cause of the incident.

29. Basic 5-Why Solution Pattern Amkor Confidential 29

30. Sample Technical RC (Non Conformance) Amkor Confidential 30 Problem : The part does not work in the ABC application 12 V output voltage is below limit (zero) The maintenance of the etching chambers is not frequent enough to be effective, 1x a day only There is an open connection on the traces There is an FM below the metal The etching process is insufficient to remove the XX size metal T hu s T hu s T hu s T hu s T hu s W hy ? W hy ? W hy ? W hy ? This is a Technical occurrence root cause 5 Why’s is not finished here: You need to understand why the organization did not predict Failed to inspect Non conformance on procedure

31. Sample System RC of TRC Amkor Confidential 31 The maintenance of the etching chambers is not frequent enough to be effective, 1x a day only Maintenance procedure is obsolete It has not been updated since last year Quality system requests an update only each 2 years, this type of equipment acquire past the review W h y ? T hu s T hu s T hu s W h y ? W h y ? This is an occurrence system root cause

32. Sample Technical RC (Non Detection) Amkor Confidential 32 Problem : the part does Test at the customer indicates an output voltage < 12 V The OS test did not detect the bad part The test program does not test the Voltage Out pin not work in the ABC application Why? W h y ? W h y ? W h y ? Not considered during test program qualification T hu s T hu s T hu s T hu s This is a Technical escape root cause 5 Why’s is not finished here: You need to understand why your organization did not predict that

33. Sample Escape System RC Amkor Confidential 33 Voltage Out Pin Not considered during test program qualification Voltage Out pin considered Non-critical Patterned on the old devices review checklist Inadequacy in the device qualification procedure, no provision on new device critical check items review W h y ? T hu s T hu s T hu s W h y ? W h y ? This is an Escape system root cause

34. Missing threads on fastener part number LB123 Did not detect threads were missing Sensor to detect thread presence was not working Sensor was damaged WHY? WHY? WHY? WHY? No system to assure sensors are working properly This is still a systemic failure & needs to be addressed, but it’s not the root cause of the lack of detection. Is this a good or bad “TRC” ? Amkor Confidential 34 What caused the sensor to get damaged?

35. Missing o-ring on part number K10001J Parts missed the o-ring installation process Parts had to be reworked No standard rework procedures exist WHY? WHY? Operator did not return parts to the proper process step after rework WHY? WHY? Is this a good or bad Escape RC? Amkor Confidential 35 Why did they have to rework? This is still a systemic failure & needs to be addressed, but it’s not the root cause.

36. Basic 5-Why Solution Pattern Template – with CAPA Amkor Confidential 36

37. Ten Basic 5WHY Rules Amkor Confidential 37

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39. Ten Basic 5WHY Rules Amkor Confidential 39 No business can be continued with this rootcause!

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45. Ten Basic 5WHY Rules Amkor Confidential 45

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47. When do I stop asking “Why” ? Amkor Confidential 47 Repeat the “why” until the answer can trigger a countermeasure

48. Ten Basic 5WHY Rules Amkor Confidential 48