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The purpose of this paper is to go a step further from the traditional 5 Whys technique by adding three more legs during the root cause analysis stage – occurrence, human and systemic issues that contribute toward the problem, hence the term 3 × 5 Whys. Performing individual 5 Whys for these three components enables to identify deeper root cause(s) that may spawn across multiple groups within an organization.

Cause-and-effect analysis used during traditional root cause investigations within an 8D or Lean six sigma project is used as a theoretical foundation. Examples from different industries are presented showing the 3 × 5 Why’s framework and advantages it brings to the organization along with identifying shortcomings and suggestions to make it more effective.

If properly used this integrated methodology will reveal higher order systemic causes (e.g. policies or management decisions) stemming from lower lever symptoms (e.g. defective parts, procedural errors). Effective execution of this methodology can provide tremendous results in defect reduction, yield improvement, operational efficiency improvement and logistics management type of projects. Resolving higher level sources of problems allows an organization to evolve itself and maintain a competitive edge in the market.

Adopting this quality management technique in start-up companies entails some challenges and other implications have been discussed with SWOT analysis.

Examples from various sectors using 3 × 5 Why approach have been presented that show that this methodology provides deeper insight into root causes which could be affecting multiple groups in an organization. Using this technique effectively is found to be beneficial to resolve issues in operations management, logistics, supply chain, purchasing, warehouse operations, manufacturing, etc.

This methodology has a human component which often results in some sort of resistance as not all working professionals think alike when it comes to accountability and ownership of issues. This may hinder root cause analysis and subsequent corrective actions implementation.

This study is unique in its in-depth real-world case studies demonstrating the need for taking a deep dive approach to root cause analysis by understanding specific, system and human components responsible for causing the failure mode.

The purpose of this paper is to reduce or eliminate the overall equipment effectiveness (OEE’s) speed loss in a lean manufacturing environment.

This action research study uses the lean manufacturing 5-whys analysis technique to reduce or eliminate the speed loss.

The application of the 5-whys analysis technique in a manufacturing industry (XYZ Corporation) completely eliminated its top speed loss and resulted in a valuable savings of USD 32,811.5 per annum.

The 5-whys analysis technique which has been primarily known to improve the OEE’s quality loss and changeover loss has been proven to be an effective approach to also tackle speed loss; a loss which has been regarded as the most dominating loss among all the types of OEE’s losses and a difficult one to eliminate.

Little or no attempt has been made to date to expand the use of the 5-whys analysis technique beyond its originally intended purpose. The lessons learnt in this study could be applied to other organizations. The outcome of the study has also opened the possibility of widening the horizon of the use of the 5-whys analysis technique beyond its original intended objective and could be applicable to solve other losses of OEE and non-value added activities of lean philosophy in general.

This paper seeks to document an approach to reduce scrap losses using the root cause analysis technique in a lean manufacturing environment.

The study uses lean manufacturing root cause problem solving (RCPS) technique. The study starts with the collection phase, followed by the analysis phase and ends with the solution phase. Supporting data are presented using a Pareto chart to prioritise wastage in order to be more focused for improvement. The Toyota Production System's 5‐whys analysis is performed to analyse the cause of wastages, to formulate and implement corrective actions.

The application of the 5‐whys analysis in a manufacturing industry (XYZ Corporation) provides a fact‐based and structured approach to problem identification and correction that not only reduces, but also totally eliminates defects. Corrective action has permanently eliminated the top defect, which is the “last piece material scratch” and this results in zero scrap thereafter. In this study it was also proven that with sound understanding of manufacturing coupled with possible solutions using the 5‐whys analysis the authors were not only able to eliminate waste, but also to do it with zero‐cost.

The approach documented in the paper can be extended to other areas in the manufacturing industry to help improve overall equipment efficiency, breakdown, time loss, customer complaints, etc.

The purpose of this paper is to explore the dynamics of critical thinking (CT) in contrast with Six Sigma and the “5 Whys” approach that is used by many managers to conduct “Root cause analysis” in business process improvements.

The research integrates principles of traditional literature review with a reflective inquiry of a practitioner.

Six Sigma and its “5 Whys” methodology is insufficient in root cause analysis unless coupled with CT. The paper demonstrates that some extraordinary business successes were achieved by CT, while catastrophic failures were often the result of selective biases, rigid thinking, and/or tendencies to deal with steps of processes, isolated processes, and/or independent situations. Consequently, the paper identifies a new domain that can be added to training in Six Sigma and 5 Whys.

The study does not address specific ways to integrate CT into Six Sigma, 5 Whys, and/or root cause analysis in business process improvement initiatives. Future research is needed in this area.

The paper explores a new perspective to convalescing Six Sigma and 5 Whys methods. It provides a specific example and suggestions to help practitioners avoid faulty conclusions, while conducting investigations to improve business processes. It also opens the door for encompassing aspects of CT in Six Sigma training. As such, it benefits both practitioners and academics.

The purpose of this paper is to present a structured framework whose objectives are to identify, analyse and eliminate fashion-luxury supply chains inefficiencies.

A Lean Manufacturing tool, the 5-Whys Analysis, has been used to find out the root causes associated with the problem identified from a data analysis of production orders of a fashion-luxury company. A case study, which explains the methodology and illustrates the capability of the tool, is provided.

This tool can be considered a suitable instrument to identify the causal factors of inefficiencies within luxury supply chains, suggesting potential countermeasures able to eliminate the problems previously highlighted. In addition, enabling technologies that deal with Industry 4.0 are associated with the root causes to enable further improvement of the supply chain.

The effectiveness and practicality of the tool are illustrated using an industrial case study concerning an international Italian signature in the world of fashion-luxury footwear sector.

This framework provides practitioners with an operative tool useful to highlight where the major inefficiencies of fashion-luxury supply chains take place and, at the same time, individuates both the root causes of inefficiencies and the corresponding corrective actions, even considering Industry 4.0 enabling technologies.

Briefly reviews previous literature by the author before presenting an original 12 step system integration protocol designed to ensure the success of companies or countries in their efforts to develop and market new products. Looks at the issues from different strategic levels such as corporate, international, military and economic. Presents 31 case studies, including the success of Japan in microchips to the failure of Xerox to sell its invention of the Alto personal computer 3 years before Apple: from the success in DNA and Superconductor research to the success of Sunbeam in inventing and marketing food processors: and from the daring invention and production of atomic energy for survival to the successes of sewing machine inventor Howe in co‐operating on patents to compete in markets. Includes 306 questions and answers in order to qualify concepts introduced.

The purpose of this paper is to establish a procedure to examine an organization's improvement process and its adverse factors.

The objectives were to find a way to represent content of a specific improvement process and analyse reliability of improvement processes conducted at operational, tactical and strategic levels. Inspirations of the text were various heuristic schemes used in a process of problem solving: to stimulate transfer of data by formulation of questions (5W or 5Why); to control the flow of the process (QC Story or 8D etc.); and to document results of operation (Ishikawa, fault‐tree diagram, and others). The outcomes are: a questioning scheme on Improvement Story by 5 Whys, which provides guidance, through a study of an organization's improvement processes related to containment, corrective and preventive type; and diagrams of the Prevention State Transitions and the Improvement Snail, which facilitate navigation through the above processes.

There is a finite sequence of Why‐questions, which can be used to analyse basic characteristics of systems of improvement processes in organizations. This scheme has a direct graphical representation in the Improvement Snail and the Prevention States Transition diagrams.

The scheme has a wide scope of applications: it can be used retrospectively or in parallel to a running process of problem solving. A context of the analysis may be auditing an improvement process or monitoring a particular improvement project.

The scheme combines various aspects of improving the effectiveness of an organization's functions. It can represent, in a systematic way, information concerning risk issues related to: the problems and their mechanisms; the effectiveness of improvement processes that are related to various levels of organization: operational, tactical and strategic and their coordination. The scheme is flexible, as it can be combined with various analytical techniques such as fault tree diagram etc. and it can be adjusted to any specific purpose, by modifying the structure and content of questions set.

The current good manufacturing practices (cGMP) are followed in the pharmaceutical sector to ensure that products are consistently produced and controlled to the appropriate quality standards as required by the marketing agencies. The purpose of this paper is to share improvement experiences due to implementation of lean principles combined with cGMP in a pharmaceutical company.

To conduct the study, an intensive review of literature has been conducted. For analysis of the problems existing in the selected production line, the 5‐whys methodology was followed. The current state value stream map (VSM) has been developed after making several company visits and necessary computations. For improvement of the system, various lean strategies have been proposed and the future state VSM developed.

The methodology assisted this company in reducing lead times, cycle times and WIP inventory in the manufacturing process. Furthermore, the storage area was reduced by 38 per cent and production staff was reduced by 50 per cent.

The prime purpose of a lean strategy is to eliminate wastes and to search for continuous improvement in processes. The proposed lean strategies indicated scope for improvement in production efficiency and effectiveness of manufacturing operations.

The guiding principle of cGMP is that quality is built into a product, and not just tested into a finished product. This paper makes several contributions to the pharmaceutical manufacturing company. The proposed lean strategies are considered to be highly valuable for implementation in similar manufacturing industries.

Statistics shows terrifying tendencies in people’ unwillingness to develop themselves by reading books. The situation is even more serious if we look at companies and their employees. People want to be specialists, but in fact reading culture in companies is rare. Many actions which are undertaken to reverse this trend may lead to sales increase of books by collecting them instead of reading them, if the quality of handbooks will not be improved. To enhance people to read, it is essential to offer them a product that would really satisfy their needs. The study presented in the paper contributes to the knowledge about some general practitioners requirements for handbooks on methods, in particular these used in quality and management. It shows also the usefulness of Kano’s model application in the new area. A case study was conducted with the application of Kano’s model to identify potential readers’ expectations of a handbook for practitioners in problem-solving methods. The research was based on sample size equal to 376 different people: managers, specialists, operators, directors, students and professors in Poland. As a result, a book on problem solving method called “5 why” was created to verify if the model really works.

It shows the usefulness of Kano’s model application in the new area of education.

Potential readers’ expectations of a handbook for practitioners in problem solving methods were identified. The research was based on sample size equal to 376 different people: managers, specialists, operators, directors, students and professors in Poland.

By taking into consideration expectations from customers, authors of books and educational services may improve their works. Both sides would make profits form this: customers – better product, authors – bigger and satisfied audience.

From many previous researches, it is known that the Kano’s model is a useful, practical tool for industries; however, studies show that it is also well applicable in providing education service. As a result of the research, a book on problem-solving method called “5 why” was created to prove if the model really works in practice.

This study provides a unique integrated diagnosis system to investigate the causes of low productivity, profitability, machinery health conditions and wear severity of medium-size biscuit industry assets in Taiz, Yemen.

The evaluation is based on an integrating of the overall equipment effectiveness (OEE) and oil-based maintenance (OBM) approaches. The data are collected using the company's operational records, interviews and observations, while the used lubricating oil samples are also collected from production lines' machineries. Scanning electron microscope (SEM) is used to study the wear debris particle features and wear mechanism. Different other analysis tools such as fishbone, 5 whys and Pareto charts are also used to investigate the root causes and plausible recovery solutions of machinery failures.

This study demonstrated that a large proportion of machinery failures and production loss are of management concerns. Also, this study inferred that the analysis of wear debris is unique and informative for determining machinery wear severity and useful life. Finally, the current conditions of production lines are clarified and suggestions to use a mixed preventive/predictive maintenance management approach are also elucidated.

This work implemented an integrated OEE/OBM diagnostic maintenance system to investigate the root causes of low productivity and machine failures in real production lines and suggested robust decisions on the maintenance duties.