Run a 5 Whys That Ends in Process Change
Use 5 Whys to move from a narrow defect symptom to a process-level countermeasure.
A torque audit found 11 loose screws on bracket model B-17 during second shift. 5 Whys: symptom -> process condition -> verified cause -> countermeasure The common trap is stopping at 'operator missed it.' That labels a person but does not explain why the process allowed the miss. Why 1 Why were screws loose? The torque driver clicked, but the screw did not reach seated torque. The first why stays close to the observed defect and avoids judging the operator. Why 2 Why did the driver click without seating? The bit slipped in the screw head on several attempts. The…
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