Creating a SIPOC Chart
February 12, 2025
Abstract The three imperatives of sufficiency, safety, and sustainability of the global energy paradigm as it exists now along with the need to transition to a new energy paradigm are the two themes that are analyzed and evaluated in this report. The fact that the existing oil based paradigm has led to wars and conflicts […]
Israel is one of the youngest countries in the world. It has been in existence for only 72 years. While many of its peers such as India and Pakistan are still developing nations, Israel has quickly climbed the ladder. Israel is not considered a developed nation. This is because the per capita income in Israel […]
Business Process Improvement projects can be applied to any and every process in any industry. Using BPI it is possible to increase the efficiency of any and every process. Processes though designed well, can become inefficient over a period of time. Besides, processes need to be subject to review periodically to determine the efficiency as […]
Introduction Product quality determines the success with the product. One of the key drivers of quality is the performance of the product over a period of time. Performance of product is determined by the reliability and redundancy. Reliability increases the efficiency while redundancy increases the current capability and expectations. Any production organization sets a goal […]
Globalization of Supply Chains and its Implications We have discussed how the globalization of the world economy has made the globe more integrated and interconnected. While this has both positive and negative effects on the way global trade and commerce takes place, there is one critical aspect that needs our attention. That is to do […]
The Five Why’s analysis, also known as the root cause analysis is one of the seven basic tools that are used in Six Sigma.
The principle idea behind the tool is the fact that for every effect there is a cause. Therefore the quality problem can be viewed as an effect for which there will be one or multiple causes. However, it is also known that there is a whole chain of reactions called symptoms before the cause actually reaches its effect. Therefore if the management is able to pinpoint and solve the problem from its root cause, considerable advantages would be gained.
Jeff Bezos Amazon Example of Application of Five Why’s:
Jeff Bezos illustrated, how the Five Whys can be used. He had visited one of the shop floors at Amazon. On his visit he saw that the fingers of one of the employees was caught in the conveyor belt and the employee had sustained injuries. Below is an account of the meeting in which Mr Bezos discussed this incident.
Question: Why did the associate damage his thumb ?
Answer: Because his thumb got caught in the conveyor.
Question: Why did his thumb get caught in the conveyor?
Answer: Because he was chasing his bag, which was on a running conveyor.
Question: Why did he chase his bag?
Answer: Because he placed his bag on the conveyor, but it then turned-on by surprise
Question: Why was his bag on the conveyor?
Answer: Because he used the conveyor as a table
So, the likely root cause of the associate’s damaged thumb is that he simply needed a table, there wasn’t one around, so he used a conveyor as a table. To eliminate further safety incidences, we need to provide tables at the appropriate stations or provide portable, light tables for the associates to use and also update and a greater focus on safety training. Also, look into preventative maintenance standard work.
The Five Why’s act as a powerful tool and help in sifting through the symptoms which represent surface level problems to the real problem, the root cause. Solving this root cause solves all the problems in between.
The Five Whys process is only semi-structured. This means that if it is done by different people, they may come to very different results. The process therefore is only as good as the person running it. This makes it important to ensure that the team is cross functional and really involved in obtaining best results for the process.
Although the 5 Why’s is an elementary tool when it comes to six sigma methodology, it is nonetheless important. Since there is a high degree of subjectivity involved with the usage of the tool, it is suggested that it be used only by a team of cross functional experts to obtain best results. Here is the list of the steps to follow to get best results:
It is therefore important that the problem be framed in the correct manner. As the old saying goes “A problem well defined is half solved”.
The definition of the problem should be objective i.e. it must include facts and measurements. It must leave no room for ambiguity for words like “more”, “less” etc.
Its only when the problems can be defined in concrete numerical terms can a desired solution be defined and worked upon.
Many times brainstorming sessions do not work because there is deliberate shielding of problems by departments to avoid being penalized for being inefficient in the past.
It should be ensured that the participants are indeed objective. There must be no penalties on bringing out past and present shortcomings, instead it must be encouraged.
Also the rules of the discussion must be made clear prior to beginning the process. The focus must always be on results and not the people involved. Organizations that move beyond people are the ones that succeed with their six sigma endeavors.
For example A causes B, B causes C and C causes D. In this case A is a Level 1 cause, B is a level 2 cause and C is a level 3 cause when it comes to solving D as a problem.
Solving A would pull the rug beneath all other issues and the management will be able to use much more with limited resources than it would otherwise have done.
A six sigma process does not allow error even if the participants willfully want to err. Hence the root cause analysis should ensure that it is not degenerating to a finger pointing exercise.
The idea should be to make the system so efficient that it does not allow any errors whatsoever.
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