Why Toyota

Naze-Naze Analysis (5 x Why)
5 x Why - Five Times Why

The basic for all engineering / quality works
Internal |AE/QMC | 20.Oct.2005 | Filing Note | 2005. All information contained herein are the properties of Bosch Automotive Systems Corp.
We reserve all rights.
Introduction (1/2)
Problem
What is Naze-Naze?
Naze is a Japanese word to question Why?.
Because it is recommended to repeat at least 5 times, it is

known also as 5 x Why (five times why) .
Why
Why
Why
Why
Why
Root cause
2
Deeper and deeper
Naze-Naze Analysis is a well known technique in problem

solving to find out real root causes by repeatedly asking
Why? deeper and deeper.
Introduction (2/2)
5 x Why is also requested in Bosch Corporative Directive QSP0508 Problem
Solving with the 8D Method.
Many people say Of course, I know 5 x Why!.

But: Do you use it in reality? Are you sure that your 5 x Why is correctly done?
Link to QSP0508:
http://www.intranet.bosch.com/zq/ZQF/qsp/englisch/Qsp0508e/QSP0508e.pdf
Historical background
One of Ohnos habits was to repeat asking
Why the problem happened
Why the problem was prevented
-whywhy-why-why..
until the real root cause was found.
This habit has been preached to overseas
transplants of Toyota.
All Toyota employees are trained through their daily
jobs to find out problems, root causes,
countermeasures in this way. His habit became a
Toyotas culture.
Mr.KAIZEN Taiichi Ohno (1912-1990)
This culture is one of the keys of Toyotas success

today, that are realized by enthusiastic problem
finding skill of every employee.
His philosophy is still alive in today's Toyota way.
A former director of Toyota who established

Toyota-Production-Sytstem, which is known by
Kanban.
Link to the information source:

http://www.asahi.com/jinmyakuki/TKY200509290213.html
Why Naze-Naze?
[Saihatsu Boushi]
Reoccurrence prevention
Goal:
Grasp the real root cause to prevent a reoccurrence
By implementing 5 x Why, you will be able to make GOOD products
protected by cost-optimum, fast and effective counter-measure to remove the
real root case.
What to do?
Investigate at Genchi with Genbutsu
[Genchi Genbutsu]
Where the problem happened,
the product with problem
Key point:
[Gemba] = On-Spot principle

It is important that investigations are
done at where the problem happened,
i.e. shop-floor, packaging area,
Do not think in the office
production line, etc..
5
Go to GEMBA!

1. Target of improvement of Naze-Naze skill
It is necessary to make a countermeasure in a short time when a problem happens. Also customers
require to report in 1-2-14 rule. In order to make a countermeasure, it is necessary to know the root
cause. Therefore we use Naze-Naze analysis as a problem solving tool, however we often make
inefficient or untimely countermeasures because we did not grasp the real root causes. This is why
we need to learn the proper way of Naze-Naze Analysis.
2. What is Naze-Naze?
Think
Think Why
Why itit happened.
happened. At
At least
least repeat
repeat 55 times.
times.
II left
left home
home
late
late
II came
came to
to the
the
office
office late!
late!
Wh
II got
got up
up late
late
My
My alarm
alarm clock
clock
didn`t
ring
didn`t ring
Why
Why
Why
Visible
phenomenon
(surface)
Reference: JC/MOE2 training material
The
The battery
battery
had
not
had not been
been
replaced
replaced
The
The battery
battery
was
was dead
dead
Why
Real root cause
II came
came to
to the
the office
office late!
late!
Superficial
Visible
phenomenon
(surface)
Why?
II left
left home
home
late
late
II got
got up
up late
late
My
My alarm
alarm clock
clock
didn`t
ring
didn`t ring
The
The battery
battery
was
was dead
dead
Countermeasure
Leave
Leave home
home early
early
Get
Get up
up early
early
Make
Make the
the alarm
alarm clock
clock ring
ring
Replace
Replace the
the battery
battery
Real root cause
Deep
Right countermeasure
Problem solved!
The
The battery
battery
had
not
had not been
been
replaced
replaced
Replace
Replace the
the battery
battery regularly
regularly
Improper
countermeasure
= Risk of
reoccurrence

3. How to make 5 x Why
Phenomenon
Phenomenon
Step
Step 11
Step
Step 22
Confirm
Confirm ifif there
there is
is no
no contradiction
contradiction
Step
Step 33
Step
Step 55
Root
Root cause
cause
Step
Step 44
Countermeasure
Countermeasure
Effectiveness
Effectiveness
confirmation
confirmation
Important!
Analyze in
4M and
5W1H
It must
make
sense A
happened
because
of B
Judge if there will be

no reoccurrence
Analyze in
Genchi
Genbutsu
Review the effectiveness

if the countermeasure
eliminated the root cause

4. Naze-Naze Analysis: Good and bad example
Step 1
GOOD
I left home late
Step 3
I got up late
Step 4
My alarm clock
didn't ring
Because
Because
I came to the
office late!
BAD
Step 2
Step 5
The battery
was dead
Because
Because
It is possible to go back the story with Because
There was a
traffic jam
There was an
accident
Because
I took a
different way
Because
It was raining
Because
It is not possible to go back the story with Because
The battery
had not been
replaced

Way of thinking
Comments
Start investigation immediately (in a day) since a problem is known.
The status of failed parts and Genchi will be changing by

time. Investigate before the status changes.
Investigate in the following dimensions:

- Why did the failure occur?
- Why was the failure delivered to customer? (Outflow Ryushutsu)
C/M on the root cause should be prioritized than easily

adding check gates.
Failure phenomenon Estimate root causes Prove with

Genchi-Genbutsu repeat least 5 times until the real root cause.
Start from 1 phenomenon.
If the failure mode is not clear, perform 100% inspection until the
failure mode becomes clear and analyze until the R/C is grasped.
Gather failed parts by 100% inspection and analyze

them. As long as the real R/C is grasped, potential
failures are continuously produced.
It is the best if only one C/M is done on the real root cause.
There is little possibility that two different R/Cs happen at

once.
Verify if the failure phenomenon Root cause

Countermeasure is logically correct or not.
Check if the story has any contradiction or not.
C/M
Avoid unnecessary C/M.
Minimize C/M just for more margin or more POKAYOKE.

Find out the optimum C/M in total of production
(Tsukurikomi)/design/outflow.
Effectiveness
of C/M
Confirm that the C/M works perfectly.
Never allow a reoccurrence with the identical R/C.
General hint
Analyse carefully in-line failures.
If a R/C is found out from in-line failures, it will be the

best in time, safe and cost!
R/C analysis
R/C: Root Cause
10
C/M: Countermeasure
R/C analysis
Way of thinking
Comments
Start investigation immediately (in a day) since a problem is known.
The status of failed parts and Genchi will be changing by

time. Investigate before the status changes.
Investigate in the following dimensions:

- Why did the failure occur?
- Why was the failure delivered to customer? (Outflow Ryushutsu)
C/M on the root cause should be prioritized than easily

adding check gates.
Failure phenomenon Estimate root causes Prove with

Genchi-Genbutsu repeat least 5 times until the real root cause.
Start from 1 phenomenon.
If the failure mode

is not clear, perform 100% inspection until the
failure mode becomes

clear and analyze until the R/C is grasped.
[Ryushutsu]
Gather failed
parts by 100% inspection and analyze
[Pokayoke]
them. As long
as the real R/C is grasped, potential
arePokayoke
continuouslycan
produced.
prooffailures
system.
also be creatively
Fool
Outflow of failures. Failures are not detected
proposed
by Kaizen activities from Gemba
with
RBbest
andif only
delivered
toiscustomer.
It is the
one C/M
done on the real root cause.
There is little possibility that two different R/Cs happen at
operators.
once.Not necessarily very sophisticated.
Verify if the failure phenomenon Root cause
Countermeasure is logically correct or not.
Check if the story has any contradiction or not.
C/M
Avoid unnecessary C/M.
Minimize C/M just for more margin or more POKAYOKE.

Find out the optimum C/M in total of production
(Tsukurikomi)/design/outflow.
Effectiveness
of C/M
Confirm that the C/M works perfectly.
Never allow a reoccurrence with the identical R/C.
General hint
Analyse carefully in-line failures.
R/C: Root Cause
11
[Tsukurikomi]
If a R/C is found out from in-line failures, it will be the
Good product quality can be realized by well best in time, safe and cost!
controlled processes based on good product design.
Not only
products, but carefully make products.
C/M:make
Countermeasure
Thank you for your attention
Questions / Feedback:
Mail to: Jun Mizuno (AE/QMC)
jun.mizuno2@de.bosch.com
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Naze-Naze Analysis (5 x Why)

5 x Why - Five Times Why

Naze-Naze Analysis (5 x Why)

Because it is recommended to repeat at least 5 times, it is

Deeper and deeper

Naze-Naze Analysis is a well known technique in problem

Naze-Naze Analysis (5 x Why)

Many people say Of course, I know 5 x Why!.

Naze-Naze Analysis (5 x Why)

Mr.KAIZEN Taiichi Ohno (1912-1990)

This culture is one of the keys of Toyotas success

His philosophy is still alive in today's Toyota way.

A former director of Toyota who established

Link to the information source:

Naze-Naze Analysis (5 x Why)

[Gemba] = On-Spot principle

Naze-Naze Analysis (5 x Why)

Real root cause

Naze-Naze Analysis (5 x Why)

Real root cause

Reference: JC/MOE2 training material

Naze-Naze Analysis (5 x Why)

Judge if there will be

Reference: JC/MOE2 training material

Review the effectiveness

Naze-Naze Analysis (5 x Why)

I left home late

It is possible to go back the story with Because

It is not possible to go back the story with Because

Reference: JC/MOE2 training material

Naze-Naze Analysis (5 x Why)

Start investigation immediately (in a day) since a problem is known.

The status of failed parts and Genchi will be changing by

Investigate in the following dimensions:

C/M on the root cause should be prioritized than easily

Failure phenomenon Estimate root causes Prove with

Start from 1 phenomenon.

Gather failed parts by 100% inspection and analyze

There is little possibility that two different R/Cs happen at

Verify if the failure phenomenon Root cause

Check if the story has any contradiction or not.

Avoid unnecessary C/M.

Minimize C/M just for more margin or more POKAYOKE.

Confirm that the C/M works perfectly.

Never allow a reoccurrence with the identical R/C.

Analyse carefully in-line failures.

If a R/C is found out from in-line failures, it will be the

R/C: Root Cause

Naze-Naze Analysis (5 x Why)

Start investigation immediately (in a day) since a problem is known.

The status of failed parts and Genchi will be changing by

Investigate in the following dimensions:

C/M on the root cause should be prioritized than easily

Failure phenomenon Estimate root causes Prove with

Start from 1 phenomenon.

If the failure mode

failure mode becomes

Check if the story has any contradiction or not.

Avoid unnecessary C/M.

Minimize C/M just for more margin or more POKAYOKE.

Confirm that the C/M works perfectly.

Never allow a reoccurrence with the identical R/C.

Analyse carefully in-line failures.

R/C: Root Cause