Fishbone - 5 Why Checklist

Investigation Notes

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Method

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Work Instructions incomplete, inadequate and not precise.
  (Set up Sheet, Tool Sheet, Program Instructions, Quality Plan)

  0

  1

  2

  3

  5

• Are the Inspection methods adequate & acceptable?
  

  0

  1

  2

  3

  5

• Are the Feeds & Speeds viable for the designated tooling?

  0

  1

  2

  3

  5

• Part fixture & part location surfaces not cleaned prior to loading the part.
  

  0

  1

  2

  3

  5

• Program/process changed during or from last time job was run.

  0

  1

  2

  3

  5

• Operation performed out of sequence.

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Measurement

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Inspection methods inadequate & unacceptable.
  

  0

  1

  2

  3

  5

• Gauging inadequate for the dimensions called out?
  (Type, Resolution, Repeats, Can accurately measure the dimension)

  0

  1

  2

  3

  5

• Gages out of Calibration date.
  

  0

  1

  2

  3

  5

• Gage allows incorrect readings
  

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Machine

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Coolant and coolant levels inadequate and does not meet the requirements.
  

  0

  1

  2

  3

  5

• Coolant added to machine during process.
  

  0

  1

  2

  3

  5

• Machine not capable to produce the operation requirements.
  

  0

  1

  2

  3

  5

• Machine malfunction.
  

  0

  1

  2

  3

  5

• Tooling/Tool holders inadequate to produce the dimensions.
  

  0

  1

  2

  3

  5

• Tooling/Tool Holder worn.
  

  0

  1

  2

  3

  5

• Fixture inadequate and unload friendly.
  

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Material

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Incorrect Material being used.
  

  0

  1

  2

  3

  5

• Material hardness not within the required limits?

  0

  1

  2

  3

  5

• Material not within the Blueprint requirements?
  

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Mother Nature

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Power failure.
  

  0

  1

  2

  3

  5

• Power surge.
  

  0

  1

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  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

Man

• 0 = No affect, 1 = No Affect, but can be improved, 2 = Minor cause, 3 = Secondary Cause, 5 = Primary cause.

• Associate does not understand all the work instructions.

  0

  1

  2

  3

  5

• Associate did not follow all of the work instructions.
  

  0

  1

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  5

• Associate does not have enough experience/training to perform task.
  

  0

  1

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  3

  5

• Associate performing more than one task (IE: double machine).
  

  0

  1

  2

  3

  5

• Loading method not maintained.
  

  0

  1

  2

  3

  5

• Associate not following the method of double checking.

  0

  1

  2

  3

  5

• Gage being read incorrectly.
  

  0

  1

  2

  3

  5

• None of the Above - Added Cause:

Blank Cause

• Select Affect Level and Enter Description in Text Box

  0

  1

  2

  3

  5

5 Why

• By repeatedly asking the question "Why" (five is a good rule of thumb), you can peel away the layers of symptoms which can lead to the root cause of a problem. Actions may be applicable at different levels of the root cause. Action at root cause must be identified to prevent reoccurrence.

5 Why - Why did the problem occur?

• Why 1 - Why did this occur?

• Why 2 - Why did why 1 occur?

• Why 3 - Why did why 2 occur?

• Why 4 - Why did why 3 occur?

• Why 5 - Why did why 4 occur?

• Root Cause/Corrective Action:

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5 Why - Why was the problem not detected?

• Why 1 - Why did this occur?

• Why 2 - Why did why 1 occur?

• Why 3 - Why did why 2 occur?

• Why 4 - Why did why 3 occur?

• Why 5 - Why did why 4 occur?

• Root Cause/Corrective Action:

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5 Why - Why did the Quality Management System fail?

• Why 1 - Why did this occur?

• Why 2 - Why did why 1 occur?

• Why 3 - Why did why 2 occur?

• Why 4 - Why did why 3 occur?

• Why 5 - Why did why 4 occur?

• Root Cause/Corrective Action:

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