Occurence

Material Mean Medium

Defective product arrived from tier 2 supplier Inappropriate manufacturing mean Inappropriate lighting
Product damaged after control Alternate mode on manufacturing mean Too noisy
Reliability defect - could not be seen at 0 km No start-up check of pokayoke Inappropriate manufacturing conditions
Defect only when manipulating / dynamic testing Bypassed pokayoke (key on pokayoke) Crisis on this item
Disturbance due to rework on close parts Overflow
Undetected drift of a caracteristic Crisis on other item with impact
Product is conformant, but specification too low on issue
Unrespected FIFO
Add more causes if needed… Add more causes if needed… Logistics issue Problem description:
Add more causes if needed…
Operator medically unable
Work instruction unclear Untrained operator
Time allowed for operation is not adapted Unauthorized worker
Work instruction not respected Skill matrix out of date
Operator could not access work instruction Operator did not respect work instruction
Current procedure is inappropriate/does not exist Operator did personal move See causes of non-detection
Procedure not respected Operator sick when at workstation
Most recent audit shows a non conformity Poor communication (teamleader->worker)
X Missing specific software Start-up checklist not filled in Defect generated by control
Add more causes if needed… Defect is close to pause
Social issue during production Add more causes if needed…
Methods Add more causes if needed… Measurement
Manpower
5 WHY analysis (must be conducted on the more likely causes)

Potential Cause Check Why Check Why Check Why Check Why Check Why Action Who Date

* "Check" has to be based on tests & data to confirm the root cause. => Y = Actual cause / N = Not root cause
In case root cause can not be determined, propose potential root cause
Action plan must be related to root causes - please color the causes your actions are related to