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Corrective Action

with Responsibility Date


5 Whys Study
Define symptom 5-Why:
“A problem well defined is a problem half solved”
Specific problem:
Use this path for
the specific
–Why did we have the problem?
A
Short Mould nonconformance
Problem not detected:
being investigated
–Why did the problem reach the Customer?
(Define Problem)
System failure:
–Why did our system allow it to occur?
Non conformance parts found
at customers assembly line

WHY? Therefore

Root Causes
1.Lack of monitoring on
Machine setting problem . temperature setting.
Pre heating time too short

Therefore
WHY? 2.Operator not made aware of
temperature & pressure setting.

Machine operator did not check and not


Use this path to investigate aware of temperature setting. 3.No guide line for operator
why the problem was not
should temperature & pressure
detected
level deviate from master
WHY? Therefore setting. B
Temperature and parametrer
Loose sampling method was master setting is kept by
adopted production supervisor

WHY? Therefore WHY? Therefore

Temperature and pressure of


Defects not included in machine is not monitor regularly.
Pre heating time too short A
inspection criteria.

Therefore Problem definition

WHY?

Use this path to investigate No records of defects recorded in the


the systemic root cause past
(Quality System Failures)
WHY? Therefore

Inspectors overlook this OS did not enphasis on defects


defects. (short mould )
C
WHY? Therefore WHY? Therefore

Loose inspection method was Loose sampling method and no


adopted. records of defects found in the
past. B
Next
Reported by WHY? Therefore

Break Point
Checking criteria in OS did not enphasis
on this defects.

Date WHY? Therefore

Low RPN recorded in FMEA

Revision Reference PN Product / Process WHY? Therefore

No futher action required in FMEA C


Next
Problem Resolution Complete Communicate to .. Date: Process Change Break Point Date: Implement System Change Date:

Lessons
Learned:
Team
Members:

A good 5-Why will answer “Yes” to the five


PDCA questions:

“A problem well defined


is a problem half solved”

ACT
Standardize
PLAN
Understand the problem

5. Has a plan been identified 1. Is the problem statement


to STANDARDIZE and take CLEAR and ACCURATE?
all lessons learned across
products, processes, 2. Has the SYSTEMIC
plants, functional areas, etc.? root cause(s) been
identified for all legs?

CHECK
Follow-up
DO
Execute the Plan

4. Has a plan been identified 3. Has IRREVERSIBLE


to verify the CORRECTIVE ACTION(s)
EFFECTIVENESS been implemented for
of all corrective ALL root causes?
actions?