Use Five Whys to move from a recurring apparel return symptom to a controllable process cause.
A satin skirt has 27 weekend returns marked zipper faulty. The team suspects associates are missing defects before sale. Five Whys drills from symptom to root cause by asking evidence-based why questions until the team finds a controllable process cause. The common trap is turning why into who. If the chain becomes who messed up, people hide information and the process stays broken. Before Manager tells associates to inspect zippers better. Returns dip for two days, then repeat the next weekend. After Manager finds tight post-steam clipping bends zipper teeth, changes the hanger standard, and checks five units per batch.…
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