Run 5 Whys on a Cycle Count Miss
Use 5 Whys to move from count variance to process fix.
Bin A14 has 41 units physically and 64 in the system. The first explanation is "picker error." 5 Whys: symptom -> evidence -> controllable process cause The trap is stopping at the first human action. That creates retraining theater while the process condition keeps producing errors. Why 1 Why is system stock higher than physical? 23 units left the bin without a completed transaction. Use transaction history and movement timestamps, not memory. Why 2 Why was there no completed transaction? Scanner downtime forced emergency replenishment moves. The evidence shifts from picker behavior to exception process. Why 3 Why did downtime…
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