Run 5 Whys on recurring porosity
Use iterative why questions to move from a porosity symptom to a process-level corrective action.
GMAW practice coupons show recurring porosity even after the operator cleans the nozzle. Root cause analysis: move from symptom to controllable process cause before choosing corrective action. The shortcut is blaming hand skill after the first visible defect and never checking whether the setup creates the same defect for anyone. Why 1 Why are there pinholes? Gas is being trapped in the weld as it solidifies. Start with the physical failure mode, not blame. Why 2 Why is gas being trapped? Shielding coverage may be interrupted or contamination is present. List plausible cause families before narrowing. Why 3 Why is…
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