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?.
Why
Why
Why
Why
Why
Root cause
2
Internal |AE/QMC | 20.Oct.2005 | Filing Note | 2005. All information contained herein are the properties of Bosch Automotive Systems Corp.
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Introduction (2/2)
5 x Why is also requested in Bosch Corporative Directive QSP0508 Problem
Solving with the 8D Method.
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.
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.
Internal |AE/QMC | 20.Oct.2005 | Filing Note | 2005. All information contained herein are the properties of Bosch Automotive Systems Corp.
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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:
Internal |AE/QMC | 20.Oct.2005 | Filing Note | 2005. All information contained herein are the properties of Bosch Automotive Systems Corp.
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Go to GEMBA!
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
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.
Why
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
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
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.
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
Analyze in
Genchi
Genbutsu
Internal |AE/QMC | 20.Oct.2005 | Filing Note | 2005. All information contained herein are the properties of Bosch Automotive Systems Corp.
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GOOD
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
There was a
traffic jam
There was an
accident
Because
I took a
different way
Because
It was raining
Because
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.
The battery
had not been
replaced
Comments
If the failure mode is not clear, perform 100% inspection until the
failure mode becomes clear and analyze until the R/C is grasped.
It is the best if only one C/M is done on the real root cause.
C/M
Effectiveness
of C/M
General hint
R/C analysis
10
C/M: Countermeasure
Internal |AE/QMC | 20.Oct.2005 | Filing Note | 2005. All information contained herein are the properties of Bosch Automotive Systems Corp.
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R/C analysis
Way of thinking
Comments
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.
C/M
Effectiveness
of C/M
General hint
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
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.
Questions / Feedback:
Mail to: Jun Mizuno (AE/QMC)
jun.mizuno2@de.bosch.com
12
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.