3Legged

5Why
MQCTLW100

June2009

6/15/2009 0
5 Why Analysis What is it?

The 3 Legged 5 Why (3L5Y) consists of

three easy to explain steps

SPECIFIC CAUSE: Why was the specific customer

complaint created?

DETECTION CAUSE: Why did our test methods not

filter it out?

SYSTEMIC (BUSINESS PROCESS) CAUSE: Why was

the overall system weak in the first place?

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5 Why Analysis What is it?

3 Legged 5 Why?

Specific Detection Business Process

Leg Leg Leg

How did WHY? How did the WHY? WHY?

How did the
the problem business
customer escape the process enable
problem detection the Product
occur? process? Root Cause to Systemic
Product Detection be created?
Root Cause Root Cause Root Cause

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Why Use 3L5Y?

Specific Cause
Why was the customer complaint created?

Detection Cause
Why did our test methods not filter it out?

Business Process Cause

Why was the overall system weak in the first place?

Specific Root Cause Detection Root Cause People

who do
What caused the customer How did the problem escape our the work
problem? processes?
Business Process Root Cause People who
set up the
processes
What business process allowed the specific root cause to be created?

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Detection

4 Types:

Process not looking for it

Tools methods not in place
Bypassed Detection
Escaped (was detected but placed back into
product flow)

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5 Why Analysis

The Nail and the Kingdom

For want of a nail the shoe was lost

For want of a shoe the horse was lost
For want of a horse the warrior was lost
For want of a warrior the battle was lost
For want of a battle the kingdom was lost

All for want of a nail

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5 Why Analysis

5 Why on the Kingdom The Test: Reverse Logic

1st level: We lost the battle last week. The horseshoe did not have enough
Why did we lose the battle? nails in it (root cause).

2nd level: One less Warrior. It was close. THEREFORE

The warrior carrying a crucial message The shoe fell off.
that could have saved the battle did not
deliver the message to the battle planners.
Why wasnt he there? THEREFORE
The horse was unavailable for
3rd level: One less horse. He didnt have battle.
a horse to ride. There was a horse
available. Why wasnt it used? THEREFORE
A key soldier was removed from the
4th level: One less shoe. It lost a shoe battle.
and couldnt travel the distance required.
Why didnt the horse have a shoe?
THEREFORE
5th level: One less nail. The shoe fell off, The battle was lost.
because it didnt have enough nails. The
blacksmith ran out of nails. THEREFORE
The enemy took over the kingdom.

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5 Why Analysis

The Nail and the Kingdom

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5 Why Analysis

Reverse Test for Logic

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Three-legged 5 Why Analysis

Specific Detection
Business Process

Specific: Why did this specific situation happen?

Detection: Why was the situation overlooked?
Business Process: Why did the possibility exist for this
situation to occur?

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The Kingdom and the Nail

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The Kingdom and the Nail

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The Kingdom and the Nail

Result

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3 Leg 5 Why Analysis Template

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Engine Ticking Noise @ 600 RPM

Result All engines

exhibit a ticking
noise during
warm up at 600
rpm
The piston
Why? assemblies are
making noise
There is too much
Why? clearance that exists
@ 600 RPM between
the piston pin &
connecting rod when
cold
Root Cause

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Engine Ticking Noise @ 600 RPM
Result
Clearance issue on
the assemblies
was not detected
in the test lab
Current validation
test passed
Why?
without detecting
noise
Test spec of 800 RPM
Why?
is different than what
is occurring in the
field (600 rpm)
Test spec is
Why?
carry over from
prior model
years

Root Cause
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Engine Ticking Noise @ 600 RPM

Result
The 600 RPM test
specification did
not exist
Project planning changed the
Why? requirements from the
original plan due to a change
in CAF standards, but the
changes were not
communicated to engineering
lab personnel
The change
process is
Why?
manual and
inefficient
Root Cause

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3-Legged-5-Why (3L5Y)
3-Legged-5-Whys (3L5Y) Approach
Approach for for
Product
Product Development
Development Issues Issues

Product Detection Business Process

Root Cause Root Cause Root Cause
Why was the What business /
What is the physical physical root cause engineering process caused
root cause of the NOT detected ? the detection system and
customer complaint ?
Supplier Chrysler product to fail ?
(Comp/Sys) (Sys/Veh)

DV PV S0 S1

Examples Analytical / Virtual Tests Physical Tests Examples

Material FMEA Component Tests Organization Infrastructure
Strength PF (incl. Duty Cycle) System Tests - Tools
Calibration DVP Vehicle Tests - People
Mis-alignment CAE Hot/Cold Test - Resources
Part interaction FEA Vibration Test - Skills
Fatigue CMMI Road-Test CDS
Corrosion DFSS Simulator Sourcing
Wearout Design Guidelines Proving Grounds Program Mgt
Best Practices Ride & Drive
NVH
EMC/ESD
DFSS
Note: Keep on asking WHY WHY WHY until you get to the real root cause of each of the 3 legs
(Product, Detection, and Business Process).
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So Whats the Point

Once the Data is collected, the Detection and Systemic

Leg results will be put in Pareto form and handed off to
a team that will do a deep dive analysis on the results.

Systemic Leg
Analysis of 32 Black Belt Projects System FMEA
18
20
16
14

Occurances
12
15
10
8
Count

6
10
4
2
5 0

re
d re ed te er
e ilu rm ua th
s id Fa fo de
q O
0 n n er tA
Co ct
io t P
n R er t e No No
EA
at
io CN EA P& th No et g
FM FM O
de lD PM in
if c st
V
i nt D o o
To Te
m ec
te ne M
s Sp re
Sy ce mp
o
ilu en
vi Fa ok
De Co Br
Count 20 4 3 3 1 1 Count 16 1 1 1 1
Percent 62.5 12.5 9.4 9.4 3.1 3.1 Percent 80.0 5.0 5.0 5.0 5.0
Cum % 62.5 75.0 84.4 93.8 96.9 100.0 Cum % 80.0 85.0 90.0 95.0 100.0

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Driving Excellence

It's not enough to identify Detection and System root causes --

Permanent corrective action must be put in place and verified. This
is our role in Supplier Quality.
There is nothing "too small" or "too complex" for 3L5W -- any
problem can cost us customers, all must be attacked.
Five Why problem solving is not new, 3L5W forces us to think
beyond the specific event to encourage change throughout the
enterprise. This leads to less problems, lower cost and happier
customers.
Like many processes, the quality of the input will determine the
quality of the output -- the quality of the input is up to you.

We are the future success of Chrysler.

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Thank You!

Any
Questions?

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