Why Why Analysis

Why Why Analysis is a method used for finding out the root cause of a problem or symptom. In this method a series of why questions are asked about the problem. And finally we will reach the root cause of the problem. Why Why Analysis is used for root cause analysis of a problem, which results in problem solving. Root cause can be obtained within 5 why in most problems.

I will explain this with an example.

In an electromagnetic coil manufacturing company there was severe recurring defect. Before explaining about the defect I will explain about the electromagnetic coil.

Electromagnetic coil contains a plastic part called bobbin, two metal parts called terminals which is inserted in to the bobbin by press fitting, copper wire which is wounded over the bobbin and a metal part called core which is inserted in to the hole of bobbin which directly pass through the coil.

The purpose of the electromagnetic coil is to induce magnetic field, through electromagnetic induction, when current pass through the coil.

I hope it’s clear about the product.

Now about the defect.

Copper wire is broken either in the winding operation or at the next stages. This defect is very severe and it will stops the functioning of the coil, since the current cannot pass through the copper wire.

Now we can do the why why analysis for finding the root cause of the defect.

Before starting why why analysis we must investigate how the defect occured.

How the defect occured?

After investigation it is found that the defect occurs at the winding or after winding operation, because this defect is not observed before winding operation. And ofcourse it will not happen. And also it’s observed that the coil breaks near the terminal. And in further investigation sharp edges where observed on the terminal where coils are hooked.

And finally we arrived at the below summary on how the defect occurs.