Run a fast Five Whys on breakage
Use Five Whys to move from visible breakage to a process-level cause.
Thirty-six bags of underlayment arrived torn across two branches. The visible damage is fork contact on the bottom row, but the pattern repeats after a pallet-pattern change. Five Whys links the visible symptom to a controllable process condition Stopping at 'forklift damage' creates retraining without changing the packaging condition that made fork damage more likely. Why 1 Why were bags torn? Forks caught the bottom-row bag corners during rack movement. This explains the visible symptom, but it is still close to the point of damage. Why 2 and 3 Why did forks catch corners? The pallet overhung the rack edge.…
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