Run Five Whys on a cord defect
Use Five Whys to connect a glass cord defect to a verified process condition and countermeasure.
A cord streak appears on 2.1% of ware from Line 1 between 14:00 and 16:00 after a brief batch-house interruption. Five Whys: symptom -> process condition -> system cause -> verified countermeasure The common trap is stopping at "poor mixing" or "operator error" before proving the process condition that allowed corded glass to reach forming. Why 1 Why did the customer-visible cord appear? Because composition variation reached the forming process during a two-hour window. The first why translates the defect label into a process condition and time window. Why 2 Why did composition variation reach forming? Because the batch restart…
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