Why-Why Analysis

１．５W1H
Classify the problem according to the 5Ws and 1 H explaining
characteristics and trends

Problem Who What When Where Which How

When Does it Tendency

Is there any In which Under what
producing tend to +, -
Difference Process, Situations or
happen in
Depending What Equipment, High,Low Conditions
product the
On who Unit or Does it
morning,
Carries out Component? Tend to
Mondays?
The task? Occur?
after lunch
Does it (Patterns?)
or when
Rely on the
hot or cold?
Operator’s
skill
 ２．Understand the structure
＊Flashlight definition diagram
Interrupter Cap
Insulation body of trolley shoe Resort

Case
Trolley shoe

Plug

Reflector mirror
Lens

Bulb

Insulant
Battery
Lens cover
３．Understand the principle and basic rules
（１）Principle
•The filament generate light due to heat

（２）Basic rules （Main rule）

•The filament has to receive an adequate
electric current
（Secondary rule)
①The filament should not be interrupted
②The battery should have certain voltage
③The electric resistance should be low
 ４．Make a Why Why Analysis－１
・Why Why Analysis is a method that pursues the root cause of the problem by
repeatedly asking, why?
Why Why Why Why

W１ W２ W３ W４ W５ Measure

Unit Nivel Sub-unit Parts

Level Level

Phenomenon
Of the failure
 Make a Why Why Analysis－２
・Once all the possible causes have been identified through the Why Why
Analysis, you have to study each one and its relationship with the site
And the problem object. You start to analyze the W1 level. If there is some
Cause listed, write down NA (Not Applicable) if there isn’t, write down a ○.
Probable cause - verify Probable cause - verify Probable cause - verify

Check

Check
Check

W-1 W-２ W-３ W-４・・・

¡Problem!×

× × ×
Phenomenon

○
Does not
require revision

○ Verify the W-1 level whys, if there is a problem

verify W-2. If there is no problem, the
verification should end there.
 Why Why Analysis Format

Phenomenon W１ Result Ｗ２ Result W３ Result W４ Result W５ Result

Why-Why Exercise
 Transport After chucking, the product drops during transport.

Phenomenon Why c Why d Why e

After chucking, a Downward force on
the product is stronger The gripping force of The chucking force of
product drops during
than the gripping force the hand is too weak. the hand is weak.
transport. of the hand.

Contact surface
between the hand and
hand the product is small.

movable side Downward force on

The product weight
the product is too
increased.
strong.

fixed side bottle

Transport speed of the

product is too fast.
receiving stand

elevator
 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Phenomenon Why c Why d Why e

The bottle was gripped Downward force on
the bottle is stronger The hand gripping The hand is weakly
by the hand then
than the hand gripping force is too weak. pressed to the bottle.
dropped. force.

Contact surface
between the hand and
the bottle is small.
 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Why c
Downward force on
the bottle is stronger
than the hand gripping
force.

Downward force on The bottle weight

the bottle is strong. increased. OK
 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.

Why f Why g
Contact surface
The bottle was held at The hand was
between the hand and
a slant to the hand. declined. OK
the bottle is small.

When gripped, the

bottle was declined.

The top head of the The bottle was gripped

bottle is low to the during upward OK
hand. movement.

The bottle was not

raised to the end.

The hand position was

higher than the upward
Abnormal material moving end of the OK
was inserted between OK bottle.
the hand and the bottle.

Rubber with the hand

was hardened. OK
 After chucking, a product drops during transport.
Malfunction description: The hand holds a bottle but drops it when the elevator moves downward.
Why h
Why i
Clearance between
When gripped, the top end of the The hand was Recurrence
the bottle was bottle and the fixed deviated OK
declined. side of the hand was horizontally. prevention
too large. Why j Why k Why l measures
Clearance
The bottle top between the Make a special use
The bottle was Recurrence
end interfered receiving stand Not exclusive for NG stand. Alternatively,
deviated prevention
with the fixed of the elevator the bottle. improve the
horizontally. measures and the bottle is
side of the hand. receiving stand to
large.
be adequate for the
bottle.
The bottle was
declined on the OK
receiving stand.

Resistance force
was stronger Resistance force
than the upward to the elevator The rod is bent. OK
force to the was strong.
elevator.

Air at the
pressed side OK
remains.

Resistance acts
between an
inside wall of the OK
air cylinder and
the piston.

Elevator upward
moving force is
Piston pressing OK
force is weak.
weak.
 Package process
The cap head is
collapsed at the press-
fitting process of the cap.
Note
Fully observe collapsed
cap head to classify
phenomenon as shown
in the figure for analysis.
When the state written in
the column of
phenomenon was not
observed, start to
analyze at the step just
before (that is, cap head
was collapsed.)
The cap head was collapsed at the press-fitting process of the cap.
Phenomenon Why c Why d
Guide inside the press- The cap was declined excessively.
The cap was pressed at fitting block failed to
the declined state. move the cap
horizontally. Resistance occurred between the cylindrical section
of the cap head and the press-fitting block guide.
Diameter at the bottom side of the press-fitting
block is smaller than the cap external diameter.
The center of the bottle is deviated horizontally
to the center of the press-fitting block.
The press-fitting block is declined.
The press-fitting block is
declined to the bottle.
The bottle is declined
The press-fitting margin at the cap and the bottle
The cap was forcedly Resistance between the was increased.
pressed at stopping in cap and the bottle was
the press-fitting process. strong.
The cap surface is rough.
Elongation in the circumferential direction of the
cap was insufficient.
The press-fitting block is lowered excessively.
The cap was pressed
over an allowable range.
The cap did not touch the bottom of the press-
fitting block.
Height of the bottle increased.
 The cap head is collapsed at the press-fitting process of the cap.
Malfunction description: The cap head is collapsed at the press-fitting process of the cap.

Phenomenon Why c
The cap was pressed to the
The cap head is Guide inside the press-fitting
press-fitting block at the
collapsed at the block prevents the cap from
declined state to the press-
press-fitting moving horizontally.
fitting surface of the block.
process of the cap.
(Occurred before
position to apply
the pressure to the
cap at normal
condition.)

press-fitting Star Wheel

block
Bottle

cap
head

Star
wheel The press-fitting block was
Bottle declined to the bottle.
 The cap head is collapsed at the press-fitting process of the cap.
Malfunction description: The cap head is collapsed at the press-fitting process of the cap.

Why c Why d

Guide inside the press-fitting

The cap was declined
block prevents the cap from OK
excessively.
moving horizontally.

Resistance occurred between the The cap surface is rough. OK

circumferential part of the cap
head and the guide of the press-
fitting block.
The cap is scratched. OK

Inside of the press-fitting block

OK
The press-fitting block bottom surface is rough.
diameter is too small for the cap OK
external diameter.
The press-fitting block is scratched. OK

The bottle center is deviated

horizontally from the center of the OK
press-fitting block.
 The cap head is collapsed at the press-fitting process of the cap.
Malfunction description: The cap head is collapsed at the press-fitting process of the cap.

Why c Why d Why e

The press-fitting A mounting part

The press-fitting
block is of the press- OK
block is
declined to the fitting block has
declined.
bottle. gotten rickety.

Recurrence
prevention
Why f Why g Why h measures
Radius R of the NG
The bottle neck zRework the
bottle neck is
touches partially No standard is star wheel
The bottle is larger than R of R of the bottle
to the neck specified for the fitting to the
declined. the star wheel neck is large.
support area of neck area.
the star wheel.
neck support bottle
area. standard.
zWhen
fabricating
the star wheel,
specify the
The star wheel standard
was fabricated value and
by referencing then
R of the star
sample bottle formulate the
wheel is small.
without NG
rule referring
reflecting the
bottle standard. the standard.
 Product defect {{ not filled into ×× to the specified volume (insufficient filling)

Phenomenon Why c Why d Why e

Did not reach the specified
{{ not filled into ×× to
value before filling process
the specified volume.
(insufficient measurement)

{{ filled to ×× does Flow velocity of {{ is slow. Viscosity of {{ is high.

not reach the specified
value.
Filling pressure is low.

Filling time was short.

{{ failed to fill into ×× Resistance occurs at {{ during filling. Air in ×× is not removed.
to the specified value.

Gas generating {{ (or vapor) is not removed.

{{ solidified at the filling port (or before not

{{ adheres to the filled area)
inside before filling port
and is not removed.

{{ leaks (splashed)
before the filling port (or
at the filling port, etc.)
 {{ not filled into ×× to the specified volume (insufficient filling).
Malfunction description: Unfilled area appeared near the gate of mold product.

Phenomenon Why c Why d Why e

Unfilled area appears Measured volume is too little. OK
Resin density near the Filled resin volume itself
near the gate of mold
gate is too small. is too little. Reverse flow occurs in the
product. OK
cylinder.

The gate temperature of

The gate is solidified OK
the mold is low.
before filling resin.
Resin temperature is too
OK
low.

Injection speed is too slow. OK

Switch timing from
Resin flows backwards
injection to cooling was
before solidifying the gate.
too quick.
Pressure lowered more
quickly than pressure
OK
reduction in the specified
time.
Why f Why g
Injection time, if extended,
Specified value of the
causes generation of a
injection time is too short.
burr on the molded
product at the center of
the mold.
Why h
Parting surface (mating
surface) in the cavity at
the mold center is
deteriorated.

Why i
No standard for mold
repair is specified.

NG

Recurrence prevention measures

• Improve the parting surface
(mating surface).
• Extend the injection time.
• Determine the standard to
improve the mold when a certain
amount of burr is generated at the
cavity of the mold center.
 {{ not filled into ×× to the specified volume (insufficient filling).
Malfunction description: Unfilled area appeared near the gate of mold product.

Phenomenon Why c Why d Why e Why f

Unfilled area appears Gas volume generated
Gas is retained near the Resin involved gas
near the gate of mold
gate. generated from the resin.
from the resin was too Resin absorbed water. OK
product. much.

Resin deteriorated inside

the cylinder.
OK

Originally resin has low

molecular weight.
OK

Air at the spool is moved

Resin involves air.
back to the cavity.
OK

Air is leaked more slowly Injection speed is too fast. OK

than filling speed of the
resin in the cavity.

Air is difficult to blow from

the air vent.
OK