Run 5 Whys past the first operator answer
Build a 5 Whys chain that ends in a fixable process condition.
After lunch, hot sauce fill weights swing widely for 25 minutes even though the operator uses the same filler settings as the morning run. 5 Whys: each why asks why the previous factual condition occurred, moving from symptom to mechanism to controllable condition. The team stops at 'operator adjusted it wrong,' which is not supported by the morning run and leads only to retraining. Why 1 Why are fills swinging? Because product flow through the piston filler is inconsistent after restart. This moves from the symptom to the immediate mechanism. Why 2 Why is flow inconsistent? Because sauce viscosity is…
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