April 6, 2025 • 27 mins
In this deep-dive episode, we explore the transformative impact of the 5 Whys technique—reimagined as 5+Whys—for quality assurance and root cause analysis in manufacturing. Host Donna sits down with Dr. Thinkman, QA innovation expert from PRIZ Guru, to uncover how this method goes far beyond a simple questioning tool.
Together, they discuss how the 5+Whys technique helps teams reach the heart of persistent problems, generate actionable solutions, and drive continuous improvement across semiconductors, chemistry, and metallurgy industries. Dr. Thinkman shares insights on creative thinking, avoiding superficial fixes, and leveraging tools like machine-assisted analysis and structured idea evaluation. You'll also hear real-world examples of how the technique has improved yield, reduced defects, and fostered innovation in complex manufacturing environments.
Whether you're a quality leader, engineer, or process owner, this conversation will shift your thinking about problem-solving—and why asking "Why?" is just the beginning.
#RootCauseAnalysis #5Whys #QualityAssurance #ManufacturingInnovation #ContinuousImprovement #ProcessOptimization #PRIZGuru
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Transcript
Episode Transcript
Available transcripts are automatically generated. Complete accuracy is not guaranteed.
(00:00):
Hello and welcome to another episode of From QA Challenges to Innovation with Prizzy.
(00:22):
I'm Debra, Senior Business Consultant here at PrizGuru, and today we're going to explore
how the Five Wise Technique can enhance quality assurance processes.
We have a special guest from PrizGuru, Dr. Thinkman, who is ready to share his insights.
Thank you so much for the warm introduction, Debra.
I'm delighted to join you today.
(00:43):
Why don't you go ahead with your first question?
Certainly, Dr. Thinkman.
Let's start with a fundamental point.
What is the Five Wise Technique, and how does it differ from other root cause analysis approaches?
The Five Wise Technique is an iterative questioning method aimed at uncovering the underlying
causes behind an issue by repeatedly asking why it happened.
(01:06):
While it is sometimes seen as just asking the question five times, it is actually a
powerful creative thinking tool that helps teams move beyond surface level symptoms and
reach a deeper understanding of why problems occur in the first place.
This method fosters a logical exploration of each cause and effect relationship, ensuring
(01:28):
that no fundamental source of the problem remains hidden.
In comparison to other root cause analysis methods, Five Wise is relatively simple to
apply and doesn't require complex tools or software.
Instead, it relies on systematic inquiry and team collaboration to analyze each potential
(01:49):
cause.
However, the value it brings goes far beyond its simplicity.
Because every why is meant to drive creative thinking and encourage in-depth exploration.
Organizations that use Five Wise effectively can capitalize on valuable insights into their
processes, often discovering both problems and innovative solutions along the way.
(02:12):
That's a helpful clarification.
Next, how can the Five Wise Technique contribute specifically to improving quality assurance
in manufacturing?
In QA context, especially in manufacturing, the Five Wise helps teams identify and eliminate
the real reasons behind product defects or process failures, rather than just fixing
superficial issues.
(02:34):
By drilling down multiple layers, you discover systemic shortcomings, perhaps in standard
operating procedures, maintenance schedules, training or even design parameters that may
not be evident from a single why.
This level of detail is crucial to implementing corrective actions that truly prevent recurrence.
(02:55):
The Five Wise Technique also instills a mindset of continuous improvement within QA teams.
Rather than seeing defects and errors as isolated events, organizations begin viewing them as
opportunities to refine processes and elevate quality standards.
Over time, this builds a culture where asking the right questions is just as important as
(03:18):
putting out the immediate fire.
Such a culture reduces waste, cuts down rework costs and ultimately leads to higher customer
satisfaction.
Interesting.
Could you elaborate on how this might look in industries such as semiconductors, chemistry
or metallurgy?
I'd love to hear examples of typical problems where the Five Wise Technique is used.
(03:41):
In semiconductor manufacturing, where the production process is incredibly sensitive
and steps are interdependent, the Five Wise is vital for diagnosing yield losses and test
failures.
You might notice defects on certain wafer lots.
Ask why they appeared.
Trace it to a machine calibration issue.
(04:01):
Then ask why the calibration was off.
Identify that maintenance schedules were neglected and so on until you reach a core procedural
gap.
Addressing that gap often leads to substantial gains in yield and reliability which is critical
in the highly competitive chip industry.
In the chemical or process industries, a batch that fails to meet specifications often has
(04:26):
multiple causes, from raw material variations to incorrect process parameters.
By continuously asking why, you might learn that a sensor wasn't calibrated.
It wasn't calibrated because the standard operating procedure was incomplete and so
forth.
This not only fixes one batch problem but upgrades the entire system to avoid recurrences.
(04:50):
Similarly, in metallurgy, if a particular batch of metal shows cracks, Five Wise may
reveal issues in cooling rates or faulty equipment components, ensuring the discovered
root cause drives long-term improvements.
That makes sense.
Now we often hear that Five Wise can be too simplistic, even misleading, if we stop at
(05:12):
a cause that appears trivial.
How can we mitigate that risk and ensure the Five Wise analysis is thorough?
That's a great question as it highlights a common misconception.
Many assume that if you ask why five times, you're automatically done.
But in truth, the Five is a guideline, not a strict rule, and the real goal is to reach
(05:36):
the fundamental reason of the problem, FRP.
Some issues might require more than five iterations, hence we at PrezGuru advocate the Five Wise
approach, promoting additional questions if necessary, so that no aspect of the problem
remains undiscovered.
(05:57):
Teams should gather evidence and data to support each step of questioning instead of relying
on assumptions.
This approach ensures each why leads to a logical branch of inquiry, not just a guess.
Additionally, it's vital to involve the right people, those who know the system or process
(06:18):
intimately.
The deeper the expertise represented in the analysis, the greater the chance of discovering
all relevant factors and thereby arriving at the most accurate root cause.
Indeed, deeper exploration is sometimes needed.
Now PrezGuru has introduced a modified version of this tool, the so-called Five Pulsies.
(06:39):
How does this differ from the standard approach, and what new features does it bring to QA
teams?
The Five Plud Wise tool extends the conventional Five Wise by encouraging users to continue
asking why, until they're satisfied they've truly found that core issue.
Rather than limiting teams to five iterations, it introduces a flexible framework, allowing
(07:01):
more probing where necessary.
This more comprehensive approach reduces the chance of prematurely stopping at a superficial
answer.
Additionally, in our adapted method, a root cause isn't simply an endpoint that signals
the problem is understood.
Instead, we treat the root cause as a potential source of solutions.
(07:25):
Each stage in the Five a Plud Wise process can spark new ideas for improvement because
you're systematically uncovering how the system behaves.
This perspective is crucial in QA, where preventive measures and innovative improvements
can be created once you fully grasp how and why a deviation or defect emerges.
(07:46):
That's helpful.
I'd like to know more about this notion of the root cause being a source of solutions.
Could you give an example of how that might manifest in real-world QA scenarios?
Given that, in a chemistry lab, you discover that some of your final product batches have
inconsistent purity levels.
While standard Five Wise might stop once you realize that an uncalibrated pH meter caused
(08:11):
the deviation, our approach goes a step further and views that uncalibrated meter not just
as a problem but as an opportunity to think more creatively.
Perhaps the underlying scheduling system for calibrations could be optimized or automated.
In this sense, even as you're identifying what went wrong, you're simultaneously generating
(08:36):
potential improvements.
In the example, you might integrate an automated alert system for calibrations or even explore
advanced sensors that self-calibrate under certain conditions.
Hence, each insight from the Five Plus Wise process leads you to a broader array of proactive
solutions strengthening your QA framework.
(08:59):
Understood.
Another key feature you mentioned is the idea of machine assistance for the Five Plus Wise.
How does that integrate into QA workflows and what benefits do teams typically see?
Machine assistance refers to harnessing technology to facilitate the entire root cause analysis
cycle, from gathering data to compiling, summarizing and storing the iterative exploration
(09:23):
of why questions.
In a QA environment that often looks like having the tool automatically fetch relevant
production data or test logs, so the analysis is grounded in hard facts rather than guesswork.
Beyond mere data collation, automated tools can help rank likely causes or solutions using
(09:45):
a criteria-based scoring system.
They can prompt additional lines of inquiry or remind teams if a particular angle hasn't
been sufficiently explored.
This not only accelerates the discovery phase, but helps maintain consistency across multiple
QA investigations.
Over time, the system becomes a valuable knowledge base that can reduce the likelihood of repeating
(10:10):
past mistakes and ensure that every QA team member applies a standardized, proven methodology.
That's quite intriguing.
Speaking of ranking ideas and solutions, how does that factor into the Five Plus Wise process
and why is it beneficial in problem solving?
In Classic Five Wise, the emphasis is on uncovering the root cause, but less attention is paid
(10:31):
to systematically comparing and deciding on the best fix or improvement strategy.
The Five Plus Wise method addresses this gap by incorporating a structured idea management
process.
As possible solutions arise from each layer of inquiry, perhaps changes to equipment,
training or process flows, these ideas are collected and ranked, using criteria relevant
(10:56):
to the organization, like cost, feasibility or potential impact.
This approach fosters an evidence-based decision-making culture.
Instead of merely choosing the easiest or most obvious solution, QA teams can prioritize
solutions with the greatest potential benefit.
This helps allocate resources wisely and underscores that root cause analysis isn't complete until
(11:22):
tangible.
High impact actions are chosen and implemented.
Shifting gears a bit, what do you see as the primary advantages for QA professionals who
adopt the Five Plus Wise technique, compared to sticking with more traditional, possibly
superficial approaches?
One major advantage lies in moving from guesswork to factual, reasoned problem solving.
(11:44):
By systematically pushing for deeper insights, QA professionals gain a richer understanding
of the systems they're working with, discovering interdependencies and hidden flaws they might
otherwise miss.
This depth of understanding translates directly into more robust solutions that address the
true source of problems.
(12:06):
Another benefit is that the Five Plus Wise methodology encourages forward thinking.
When you reach a root cause, you often uncover potential upgrades and refinements that can
significantly enhance process reliability, product quality or operational efficiency.
By adopting this approach, QA teams elevate their role from merely troubleshooting issues
(12:30):
after they arise to spearheading proactive, innovative improvements in production and
development.
That resonates with the idea of continuous improvement.
Given that unexpected deviations or chronic issues can be tough to tackle, how does Five
Plus Wise help manage those types of frequent quality problems?
Recent issues such as recurring batch failures or minor but repeated product defects can
(12:54):
often be traced to deeper systemic weaknesses.
Five Plus Wise excels at revealing these underlying patterns.
Instead of writing off frequent problems as part of the baseline, teams can methodically
uncover the chain of events or processes that lead to these outcomes and isolate the shared
root cause.
(13:16):
In many manufacturing settings, as soon as a deviation or excursion occurs, a Five
Plus Wise analysis is triggered.
By making this a standard operating procedure, each incident becomes an opportunity to refine
the process in ways that mitigate or even eradicate these chronic issues.
(13:37):
Over time, adopting this method becomes a cornerstone of a quality system where systemic,
repetitive problems are progressively driven out.
That's a great point.
Could you share an example of applying Five Plus Wise to improve a chronic KPI in, say,
semiconductor or metallurgy QA?
Certainly.
In semiconductor fabrication, yield is a key performance indicator.
(14:01):
Suppose a fab's yield for a certain microchip design consistently runs below target, but
the reasons haven't been conclusively identified.
Using Five Plus Wise repeatedly with each failed batch can help engineers spot recurring
patterns.
Perhaps the root cause is correlated with a specific lithography tool's maintenance
(14:22):
schedule.
Investigating that schedule, they uncover that calibration drifts occur more often than
expected due to production pressures delaying routine checks.
Once the team realizes this fundamental connection, they can propose solutions, maybe introducing
automated calibration alerts or reallocating production so the machine has designated downtime.
(14:46):
Over time, yield levels rise back to normal or even exceed expectations because the deeper
cause of chronic drift was addressed.
A similar logic applies in metallurgy.
Consistent surface cracks in certain ingots can often be traced to imbalanced cooling
or subtle material impurities and by repeatedly applying the Five Plus Wise approach, teams
(15:10):
reveal those systemic triggers and fix them.
Excellent example.
Now, beyond correcting existing issues, how does the Five Plus Wise foster innovation
and process optimization within QA context?
By pushing teams to question the status quo at each layer of causation, Five Plus Wise
serves as a natural driver for creative thinking.
(15:31):
If a team identifies a root cause in outdated SOPs, they may seize that opportunity to rethink
and restructure an entire workflow.
In the process, they discover more efficient procedures or cutting-edge equipment that
not only resolve the current problem but also elevate overall productivity or safety standards.
(15:52):
Additionally, the act of systematically analyzing how the system fails often reveals new avenues
for improvement.
QA professionals come to understand the subtleties of a process better than anyone else.
This knowledge of each step and its vulnerabilities becomes a fertile ground for new ideas, be
(16:13):
it automating certain tests, developing advanced sensors for real-time monitoring, or introducing
AI-driven inspection systems that detect deviations faster.
In this sense, problem-solving and innovation become deeply intertwined.
From your perspective, at what stage should teams apply the Five Plus Wise technique in
(16:35):
their QA processes?
In many cases, Five Plus Wise is triggered whenever there's an unexpected deviation,
a product defect, or any event that falls outside standard control limits.
This is a well-established practice since it provides timely responses to acute issues.
The technique is very nimble, so it can be used relatively quickly to bring a cross-functional
(16:58):
team together and delve into why something happened.
However, some organizations also benefit from using Five Plus Wise in a more proactive
manner.
They might periodically examine known high-risk processes, even if there haven't been recent
incidents, to identify potential gaps or latent weaknesses.
(17:20):
By systematically applying Five Plus Wise even to hypothetical problems, QA professionals
can uncover vulnerabilities that might cause trouble down the line, thereby preventing
problems before they arise.
That's a helpful blueprint.
What do you think of the role of collaboration when using Five Plus Wise in manufacturing
(17:40):
QA?
Who should be involved to maximize results?
Collaboration is absolutely critical because each question in the Five Plus Wise chain
demands input from people who have the closest knowledge of how processes or equipment actually
work.
If only management or one department handles the analysis, they might lack the on-the-ground
(18:02):
perspective.
So it's best to involve operators, engineers, maintenance staff, QA experts, and sometimes
even suppliers, depending on the nature of the problem.
When teams have representatives from across the relevant functions, their collective wisdom
ensures that each why is tackled from multiple viewpoints.
(18:26):
This leads to more accurate causal links and a broader pool of potential solutions.
Not only does this deliver a better outcome, but it also fosters unity and ownership over
problem resolution across the organization.
Everyone shares responsibility and celebrates the improvements that come from pinpointing
genuine root causes.
(18:49):
You mentioned Priz Guru earlier.
How does Priz Guru's platform support this cross-functional team approach in QA specifically?
Priz Guru's platform is designed to facilitate a structured approach to problem solving that
teams can follow collaboratively.
It includes guided question sets that walk teams through clarifying the problem, brainstorming
(19:09):
potential causes, and then systematically applying tools like Five Plus Wise or Five
Plus Wise expansions.
Since it's all online, multiple stakeholders can contribute simultaneously or asynchronously,
eliminating many scheduling hurdles.
Moreover, Priz Guru also offers methods to evaluate and prioritize the solutions generated
(19:33):
during the process.
With each idea or proposed fix, you can rate its feasibility, cost, and likely impact on
QA goals.
This ranking keeps the team focused on the most promising interventions and helps unify
people around data-driven decisions.
The entire journey, from problem definition to the selection of a remedy, is recorded
(19:56):
in the platform, ensuring knowledge doesn't get lost and can be referenced for future
improvements.
Great!
Let's discuss knowledge retention.
How does systematically documenting Five Plus Wise outcomes benefit the QA function over
the long term?
Knowledge is vital because it turns individual problem-solving experiences into an organizational
(20:18):
memory.
If you don't record what was discovered in each step of the Five Plus Wise analysis,
you risk having the same mistakes repeated, particularly as staff move roles or new people
join by capturing the logical flow.
Each question, each answer, and the eventual solution, teams create a reference that can
(20:38):
be revisited the next time a similar issue or symptom arises.
Additionally, from a continuous improvement standpoint, these documented analyses become
case studies.
QA managers can look back over them to spot trends or recurring themes.
Maybe certain procedures or pieces of equipment pop up repeatedly as root causes.
(21:01):
This long term insight allows companies to strategically invest in systemic fixes, such
as upgrading outdated machinery or rewriting SOPs, rather than handling the same issues
multiple times.
What would you say to QA leaders who are hesitant to invest in additional training or tools
to support an enhanced Five Wise process like the one Prisguru offers?
(21:23):
It's understandable that organizations might have budget or time concerns when considering
new approaches.
However, investing in a more thorough Five Wise process is less about adding extra work
and more about amplifying the return on problem solving efforts.
The ability to quickly and effectively get to the true root cause prevents costly repeats
(21:45):
of the same issues.
Moreover, the platform's structured workflow actually saves time in the long run.
Rather than conducting scattered brainstorming sessions and maintaining separate documentation,
the QA team has a single cohesive tool that organizes their findings, streamlines collaboration,
(22:05):
and preserves critical insights.
When leaders see fewer defects and reduce downtime, they typically recognize that the
improved approach to root cause analysis was well worth it.
Let's talk about Five Plus Wise in the context of product improvement.
How does refining a system with this tool lead to better KPIs over time?
(22:26):
When a QA team thoroughly documents each analysis, they're essentially building a reservoir
of organizational knowledge.
Over time, recurring issues decline because the true sources of problems, like miscalibrations,
training gaps, or poor maintenance, are systematically addressed.
This means that crucial metrics such as defect rates or rework percentages naturally improve.
(22:51):
Additionally, having this deeper understanding of the process often reveals latent opportunities
for innovation.
Researchers might discover, for example, that a test could be automated or replaced with
an alternative method.
Implementing such improvements not only solves the immediate problem, but also elevates the
overall performance of the production line, accelerating growth in key performance metrics.
(23:17):
Speaking of performance metrics, can you share a success story of how Five Plus Wise helped
with chronic problems in manufacturing and the impact it had on the bottom line?
Certainly.
I recall a semiconductor manufacturer facing ongoing yield drops over a period of months.
Traditional approaches only offered temporary solutions, and the downtime and failed chips
(23:39):
were beginning to cut deeply into profits.
Once they shifted to a systematic Five Plus Wise framework and documented every step,
they found that much of the problems stemmed from inconsistent equipment calibration caused
by rushed production schedules.
By integrating a more intelligent machine assistance tool to flag calibration intervals,
(24:02):
they stabilized the manufacturing process, raised yields back to target levels, and
slashed their scrap-related losses.
Financially, they saw a remarkable return on investment in the form of millions saved
across the product's life cycle.
This example shows that the real value of a thoughtful Five Plus Wise approach is in
(24:23):
how it can transform firefighting into proactive, long-lasting solutions.
Ah, impressive.
Let's wrap up with a question about teams that are brand new to Five Plus Wise or Five
Plus Wise expansions.
What's your best advice for them?
If you're just getting started, keep it simple and let the logic of repeated why questions
(24:44):
be your guide.
Don't worry if you don't hit exactly Five Wise.
Go until you and your team feel you've uncovered the most fundamental reasons.
Make sure to involve people who truly understand each step of the process so your questioning
doesn't get stuck at superficial answers.
Also, embrace documentation.
(25:06):
Record you each question, each answer, and any insights that emerge, whether they're
about the root cause or potential improvements.
Reviewing that documentation is critical for learning from the process and preventing
future recurrences.
If possible, use a structured platform like PrezGuru to enhance collaboration and idea
(25:27):
evaluation, but even a shared spreadsheet is a start.
The key is to develop a culture where why is a positive, constructive inquiry, not an
accusation.
Thank you for that summary, Dr. Thinkman.
My final question is more forward-looking.
How do you envision Five-Plus Wise evolving alongside new technologies and manufacturing
(25:50):
trends?
As manufacturing grows more complex, with IoT sensors capturing real-time data and machine
learning aiding in predictive analytics, the classic Five Wise structure will be supplemented
by these cutting-edge tools.
The data collected by sensors will feed directly into root cause analyses, giving QA professionals
(26:11):
immediate and detailed insights they can use to refine their why questions.
In the broader view, I think we'll see Five-Plus Wise methods helping teams navigate this complexity
in a structured way, ensuring that technological solutions remain grounded in genuine root causes.
(26:31):
Thanks to platforms like PrezGuru and other decision support tools, a new era of deeply
informed collaborative root cause analysis is within reach.
The essence of asking why relentlessly stays the same, but the depth of data and the speed
of analysis will increase, driving more powerful transformations in quality assurance processes.
(26:56):
Wonderful insights.
As always, Dr. Thinkman, and for those listeners who are facing complex problems in manufacturing
or any other domain, remember that PrezGuru offers tools and methodologies to help teams
systematically solve problems and drive innovation.
That's right.
Thank you, Deborah, for another great conversation.
(27:17):
And thank you to our listeners for tuning in to From QA Challenges to Innovation with
Priz.
Until next time, keep innovating.
Hello and welcome to another episode of From QA Challenges to Innovation with Prizzy.
(00:22):
I'm Debra, Senior Business Consultant here at PrizGuru, and today we're going to explore
how the Five Wise Technique can enhance quality assurance processes.
We have a special guest from PrizGuru, Dr. Thinkman, who is ready to share his insights.
Thank you so much for the warm introduction, Debra.
I'm delighted to join you today.
(00:43):
Why don't you go ahead with your first question?
Certainly, Dr. Thinkman.
Let's start with a fundamental point.
What is the Five Wise Technique, and how does it differ from other root cause analysis approaches?
The Five Wise Technique is an iterative questioning method aimed at uncovering the underlying
causes behind an issue by repeatedly asking why it happened.
(01:06):
While it is sometimes seen as just asking the question five times, it is actually a
powerful creative thinking tool that helps teams move beyond surface level symptoms and
reach a deeper understanding of why problems occur in the first place.
This method fosters a logical exploration of each cause and effect relationship, ensuring
(01:28):
that no fundamental source of the problem remains hidden.
In comparison to other root cause analysis methods, Five Wise is relatively simple to
apply and doesn't require complex tools or software.
Instead, it relies on systematic inquiry and team collaboration to analyze each potential
(01:49):
cause.
However, the value it brings goes far beyond its simplicity.
Because every why is meant to drive creative thinking and encourage in-depth exploration.
Organizations that use Five Wise effectively can capitalize on valuable insights into their
processes, often discovering both problems and innovative solutions along the way.
(02:12):
That's a helpful clarification.
Next, how can the Five Wise Technique contribute specifically to improving quality assurance
in manufacturing?
In QA context, especially in manufacturing, the Five Wise helps teams identify and eliminate
the real reasons behind product defects or process failures, rather than just fixing
superficial issues.
(02:34):
By drilling down multiple layers, you discover systemic shortcomings, perhaps in standard
operating procedures, maintenance schedules, training or even design parameters that may
not be evident from a single why.
This level of detail is crucial to implementing corrective actions that truly prevent recurrence.
(02:55):
The Five Wise Technique also instills a mindset of continuous improvement within QA teams.
Rather than seeing defects and errors as isolated events, organizations begin viewing them as
opportunities to refine processes and elevate quality standards.
Over time, this builds a culture where asking the right questions is just as important as
(03:18):
putting out the immediate fire.
Such a culture reduces waste, cuts down rework costs and ultimately leads to higher customer
satisfaction.
Interesting.
Could you elaborate on how this might look in industries such as semiconductors, chemistry
or metallurgy?
I'd love to hear examples of typical problems where the Five Wise Technique is used.
(03:41):
In semiconductor manufacturing, where the production process is incredibly sensitive
and steps are interdependent, the Five Wise is vital for diagnosing yield losses and test
failures.
You might notice defects on certain wafer lots.
Ask why they appeared.
Trace it to a machine calibration issue.
(04:01):
Then ask why the calibration was off.
Identify that maintenance schedules were neglected and so on until you reach a core procedural
gap.
Addressing that gap often leads to substantial gains in yield and reliability which is critical
in the highly competitive chip industry.
In the chemical or process industries, a batch that fails to meet specifications often has
(04:26):
multiple causes, from raw material variations to incorrect process parameters.
By continuously asking why, you might learn that a sensor wasn't calibrated.
It wasn't calibrated because the standard operating procedure was incomplete and so
forth.
This not only fixes one batch problem but upgrades the entire system to avoid recurrences.
(04:50):
Similarly, in metallurgy, if a particular batch of metal shows cracks, Five Wise may
reveal issues in cooling rates or faulty equipment components, ensuring the discovered
root cause drives long-term improvements.
That makes sense.
Now we often hear that Five Wise can be too simplistic, even misleading, if we stop at
(05:12):
a cause that appears trivial.
How can we mitigate that risk and ensure the Five Wise analysis is thorough?
That's a great question as it highlights a common misconception.
Many assume that if you ask why five times, you're automatically done.
But in truth, the Five is a guideline, not a strict rule, and the real goal is to reach
(05:36):
the fundamental reason of the problem, FRP.
Some issues might require more than five iterations, hence we at PrezGuru advocate the Five Wise
approach, promoting additional questions if necessary, so that no aspect of the problem
remains undiscovered.
(05:57):
Teams should gather evidence and data to support each step of questioning instead of relying
on assumptions.
This approach ensures each why leads to a logical branch of inquiry, not just a guess.
Additionally, it's vital to involve the right people, those who know the system or process
(06:18):
intimately.
The deeper the expertise represented in the analysis, the greater the chance of discovering
all relevant factors and thereby arriving at the most accurate root cause.
Indeed, deeper exploration is sometimes needed.
Now PrezGuru has introduced a modified version of this tool, the so-called Five Pulsies.
(06:39):
How does this differ from the standard approach, and what new features does it bring to QA
teams?
The Five Plud Wise tool extends the conventional Five Wise by encouraging users to continue
asking why, until they're satisfied they've truly found that core issue.
Rather than limiting teams to five iterations, it introduces a flexible framework, allowing
(07:01):
more probing where necessary.
This more comprehensive approach reduces the chance of prematurely stopping at a superficial
answer.
Additionally, in our adapted method, a root cause isn't simply an endpoint that signals
the problem is understood.
Instead, we treat the root cause as a potential source of solutions.
(07:25):
Each stage in the Five a Plud Wise process can spark new ideas for improvement because
you're systematically uncovering how the system behaves.
This perspective is crucial in QA, where preventive measures and innovative improvements
can be created once you fully grasp how and why a deviation or defect emerges.
(07:46):
That's helpful.
I'd like to know more about this notion of the root cause being a source of solutions.
Could you give an example of how that might manifest in real-world QA scenarios?
Given that, in a chemistry lab, you discover that some of your final product batches have
inconsistent purity levels.
While standard Five Wise might stop once you realize that an uncalibrated pH meter caused
(08:11):
the deviation, our approach goes a step further and views that uncalibrated meter not just
as a problem but as an opportunity to think more creatively.
Perhaps the underlying scheduling system for calibrations could be optimized or automated.
In this sense, even as you're identifying what went wrong, you're simultaneously generating
(08:36):
potential improvements.
In the example, you might integrate an automated alert system for calibrations or even explore
advanced sensors that self-calibrate under certain conditions.
Hence, each insight from the Five Plus Wise process leads you to a broader array of proactive
solutions strengthening your QA framework.
(08:59):
Understood.
Another key feature you mentioned is the idea of machine assistance for the Five Plus Wise.
How does that integrate into QA workflows and what benefits do teams typically see?
Machine assistance refers to harnessing technology to facilitate the entire root cause analysis
cycle, from gathering data to compiling, summarizing and storing the iterative exploration
(09:23):
of why questions.
In a QA environment that often looks like having the tool automatically fetch relevant
production data or test logs, so the analysis is grounded in hard facts rather than guesswork.
Beyond mere data collation, automated tools can help rank likely causes or solutions using
(09:45):
a criteria-based scoring system.
They can prompt additional lines of inquiry or remind teams if a particular angle hasn't
been sufficiently explored.
This not only accelerates the discovery phase, but helps maintain consistency across multiple
QA investigations.
Over time, the system becomes a valuable knowledge base that can reduce the likelihood of repeating
(10:10):
past mistakes and ensure that every QA team member applies a standardized, proven methodology.
That's quite intriguing.
Speaking of ranking ideas and solutions, how does that factor into the Five Plus Wise process
and why is it beneficial in problem solving?
In Classic Five Wise, the emphasis is on uncovering the root cause, but less attention is paid
(10:31):
to systematically comparing and deciding on the best fix or improvement strategy.
The Five Plus Wise method addresses this gap by incorporating a structured idea management
process.
As possible solutions arise from each layer of inquiry, perhaps changes to equipment,
training or process flows, these ideas are collected and ranked, using criteria relevant
(10:56):
to the organization, like cost, feasibility or potential impact.
This approach fosters an evidence-based decision-making culture.
Instead of merely choosing the easiest or most obvious solution, QA teams can prioritize
solutions with the greatest potential benefit.
This helps allocate resources wisely and underscores that root cause analysis isn't complete until
(11:22):
tangible.
High impact actions are chosen and implemented.
Shifting gears a bit, what do you see as the primary advantages for QA professionals who
adopt the Five Plus Wise technique, compared to sticking with more traditional, possibly
superficial approaches?
One major advantage lies in moving from guesswork to factual, reasoned problem solving.
(11:44):
By systematically pushing for deeper insights, QA professionals gain a richer understanding
of the systems they're working with, discovering interdependencies and hidden flaws they might
otherwise miss.
This depth of understanding translates directly into more robust solutions that address the
true source of problems.
(12:06):
Another benefit is that the Five Plus Wise methodology encourages forward thinking.
When you reach a root cause, you often uncover potential upgrades and refinements that can
significantly enhance process reliability, product quality or operational efficiency.
By adopting this approach, QA teams elevate their role from merely troubleshooting issues
(12:30):
after they arise to spearheading proactive, innovative improvements in production and
development.
That resonates with the idea of continuous improvement.
Given that unexpected deviations or chronic issues can be tough to tackle, how does Five
Plus Wise help manage those types of frequent quality problems?
Recent issues such as recurring batch failures or minor but repeated product defects can
(12:54):
often be traced to deeper systemic weaknesses.
Five Plus Wise excels at revealing these underlying patterns.
Instead of writing off frequent problems as part of the baseline, teams can methodically
uncover the chain of events or processes that lead to these outcomes and isolate the shared
root cause.
(13:16):
In many manufacturing settings, as soon as a deviation or excursion occurs, a Five
Plus Wise analysis is triggered.
By making this a standard operating procedure, each incident becomes an opportunity to refine
the process in ways that mitigate or even eradicate these chronic issues.
(13:37):
Over time, adopting this method becomes a cornerstone of a quality system where systemic,
repetitive problems are progressively driven out.
That's a great point.
Could you share an example of applying Five Plus Wise to improve a chronic KPI in, say,
semiconductor or metallurgy QA?
Certainly.
In semiconductor fabrication, yield is a key performance indicator.
(14:01):
Suppose a fab's yield for a certain microchip design consistently runs below target, but
the reasons haven't been conclusively identified.
Using Five Plus Wise repeatedly with each failed batch can help engineers spot recurring
patterns.
Perhaps the root cause is correlated with a specific lithography tool's maintenance
(14:22):
schedule.
Investigating that schedule, they uncover that calibration drifts occur more often than
expected due to production pressures delaying routine checks.
Once the team realizes this fundamental connection, they can propose solutions, maybe introducing
automated calibration alerts or reallocating production so the machine has designated downtime.
(14:46):
Over time, yield levels rise back to normal or even exceed expectations because the deeper
cause of chronic drift was addressed.
A similar logic applies in metallurgy.
Consistent surface cracks in certain ingots can often be traced to imbalanced cooling
or subtle material impurities and by repeatedly applying the Five Plus Wise approach, teams
(15:10):
reveal those systemic triggers and fix them.
Excellent example.
Now, beyond correcting existing issues, how does the Five Plus Wise foster innovation
and process optimization within QA context?
By pushing teams to question the status quo at each layer of causation, Five Plus Wise
serves as a natural driver for creative thinking.
(15:31):
If a team identifies a root cause in outdated SOPs, they may seize that opportunity to rethink
and restructure an entire workflow.
In the process, they discover more efficient procedures or cutting-edge equipment that
not only resolve the current problem but also elevate overall productivity or safety standards.
(15:52):
Additionally, the act of systematically analyzing how the system fails often reveals new avenues
for improvement.
QA professionals come to understand the subtleties of a process better than anyone else.
This knowledge of each step and its vulnerabilities becomes a fertile ground for new ideas, be
(16:13):
it automating certain tests, developing advanced sensors for real-time monitoring, or introducing
AI-driven inspection systems that detect deviations faster.
In this sense, problem-solving and innovation become deeply intertwined.
From your perspective, at what stage should teams apply the Five Plus Wise technique in
(16:35):
their QA processes?
In many cases, Five Plus Wise is triggered whenever there's an unexpected deviation,
a product defect, or any event that falls outside standard control limits.
This is a well-established practice since it provides timely responses to acute issues.
The technique is very nimble, so it can be used relatively quickly to bring a cross-functional
(16:58):
team together and delve into why something happened.
However, some organizations also benefit from using Five Plus Wise in a more proactive
manner.
They might periodically examine known high-risk processes, even if there haven't been recent
incidents, to identify potential gaps or latent weaknesses.
(17:20):
By systematically applying Five Plus Wise even to hypothetical problems, QA professionals
can uncover vulnerabilities that might cause trouble down the line, thereby preventing
problems before they arise.
That's a helpful blueprint.
What do you think of the role of collaboration when using Five Plus Wise in manufacturing
(17:40):
QA?
Who should be involved to maximize results?
Collaboration is absolutely critical because each question in the Five Plus Wise chain
demands input from people who have the closest knowledge of how processes or equipment actually
work.
If only management or one department handles the analysis, they might lack the on-the-ground
(18:02):
perspective.
So it's best to involve operators, engineers, maintenance staff, QA experts, and sometimes
even suppliers, depending on the nature of the problem.
When teams have representatives from across the relevant functions, their collective wisdom
ensures that each why is tackled from multiple viewpoints.
(18:26):
This leads to more accurate causal links and a broader pool of potential solutions.
Not only does this deliver a better outcome, but it also fosters unity and ownership over
problem resolution across the organization.
Everyone shares responsibility and celebrates the improvements that come from pinpointing
genuine root causes.
(18:49):
You mentioned Priz Guru earlier.
How does Priz Guru's platform support this cross-functional team approach in QA specifically?
Priz Guru's platform is designed to facilitate a structured approach to problem solving that
teams can follow collaboratively.
It includes guided question sets that walk teams through clarifying the problem, brainstorming
(19:09):
potential causes, and then systematically applying tools like Five Plus Wise or Five
Plus Wise expansions.
Since it's all online, multiple stakeholders can contribute simultaneously or asynchronously,
eliminating many scheduling hurdles.
Moreover, Priz Guru also offers methods to evaluate and prioritize the solutions generated
(19:33):
during the process.
With each idea or proposed fix, you can rate its feasibility, cost, and likely impact on
QA goals.
This ranking keeps the team focused on the most promising interventions and helps unify
people around data-driven decisions.
The entire journey, from problem definition to the selection of a remedy, is recorded
(19:56):
in the platform, ensuring knowledge doesn't get lost and can be referenced for future
improvements.
Great!
Let's discuss knowledge retention.
How does systematically documenting Five Plus Wise outcomes benefit the QA function over
the long term?
Knowledge is vital because it turns individual problem-solving experiences into an organizational
(20:18):
memory.
If you don't record what was discovered in each step of the Five Plus Wise analysis,
you risk having the same mistakes repeated, particularly as staff move roles or new people
join by capturing the logical flow.
Each question, each answer, and the eventual solution, teams create a reference that can
(20:38):
be revisited the next time a similar issue or symptom arises.
Additionally, from a continuous improvement standpoint, these documented analyses become
case studies.
QA managers can look back over them to spot trends or recurring themes.
Maybe certain procedures or pieces of equipment pop up repeatedly as root causes.
(21:01):
This long term insight allows companies to strategically invest in systemic fixes, such
as upgrading outdated machinery or rewriting SOPs, rather than handling the same issues
multiple times.
What would you say to QA leaders who are hesitant to invest in additional training or tools
to support an enhanced Five Wise process like the one Prisguru offers?
(21:23):
It's understandable that organizations might have budget or time concerns when considering
new approaches.
However, investing in a more thorough Five Wise process is less about adding extra work
and more about amplifying the return on problem solving efforts.
The ability to quickly and effectively get to the true root cause prevents costly repeats
(21:45):
of the same issues.
Moreover, the platform's structured workflow actually saves time in the long run.
Rather than conducting scattered brainstorming sessions and maintaining separate documentation,
the QA team has a single cohesive tool that organizes their findings, streamlines collaboration,
(22:05):
and preserves critical insights.
When leaders see fewer defects and reduce downtime, they typically recognize that the
improved approach to root cause analysis was well worth it.
Let's talk about Five Plus Wise in the context of product improvement.
How does refining a system with this tool lead to better KPIs over time?
(22:26):
When a QA team thoroughly documents each analysis, they're essentially building a reservoir
of organizational knowledge.
Over time, recurring issues decline because the true sources of problems, like miscalibrations,
training gaps, or poor maintenance, are systematically addressed.
This means that crucial metrics such as defect rates or rework percentages naturally improve.
(22:51):
Additionally, having this deeper understanding of the process often reveals latent opportunities
for innovation.
Researchers might discover, for example, that a test could be automated or replaced with
an alternative method.
Implementing such improvements not only solves the immediate problem, but also elevates the
overall performance of the production line, accelerating growth in key performance metrics.
(23:17):
Speaking of performance metrics, can you share a success story of how Five Plus Wise helped
with chronic problems in manufacturing and the impact it had on the bottom line?
Certainly.
I recall a semiconductor manufacturer facing ongoing yield drops over a period of months.
Traditional approaches only offered temporary solutions, and the downtime and failed chips
(23:39):
were beginning to cut deeply into profits.
Once they shifted to a systematic Five Plus Wise framework and documented every step,
they found that much of the problems stemmed from inconsistent equipment calibration caused
by rushed production schedules.
By integrating a more intelligent machine assistance tool to flag calibration intervals,
(24:02):
they stabilized the manufacturing process, raised yields back to target levels, and
slashed their scrap-related losses.
Financially, they saw a remarkable return on investment in the form of millions saved
across the product's life cycle.
This example shows that the real value of a thoughtful Five Plus Wise approach is in
(24:23):
how it can transform firefighting into proactive, long-lasting solutions.
Ah, impressive.
Let's wrap up with a question about teams that are brand new to Five Plus Wise or Five
Plus Wise expansions.
What's your best advice for them?
If you're just getting started, keep it simple and let the logic of repeated why questions
(24:44):
be your guide.
Don't worry if you don't hit exactly Five Wise.
Go until you and your team feel you've uncovered the most fundamental reasons.
Make sure to involve people who truly understand each step of the process so your questioning
doesn't get stuck at superficial answers.
Also, embrace documentation.
(25:06):
Record you each question, each answer, and any insights that emerge, whether they're
about the root cause or potential improvements.
Reviewing that documentation is critical for learning from the process and preventing
future recurrences.
If possible, use a structured platform like PrezGuru to enhance collaboration and idea
(25:27):
evaluation, but even a shared spreadsheet is a start.
The key is to develop a culture where why is a positive, constructive inquiry, not an
accusation.
Thank you for that summary, Dr. Thinkman.
My final question is more forward-looking.
How do you envision Five-Plus Wise evolving alongside new technologies and manufacturing
(25:50):
trends?
As manufacturing grows more complex, with IoT sensors capturing real-time data and machine
learning aiding in predictive analytics, the classic Five Wise structure will be supplemented
by these cutting-edge tools.
The data collected by sensors will feed directly into root cause analyses, giving QA professionals
(26:11):
immediate and detailed insights they can use to refine their why questions.
In the broader view, I think we'll see Five-Plus Wise methods helping teams navigate this complexity
in a structured way, ensuring that technological solutions remain grounded in genuine root causes.
(26:31):
Thanks to platforms like PrezGuru and other decision support tools, a new era of deeply
informed collaborative root cause analysis is within reach.
The essence of asking why relentlessly stays the same, but the depth of data and the speed
of analysis will increase, driving more powerful transformations in quality assurance processes.
(26:56):
Wonderful insights.
As always, Dr. Thinkman, and for those listeners who are facing complex problems in manufacturing
or any other domain, remember that PrezGuru offers tools and methodologies to help teams
systematically solve problems and drive innovation.
That's right.
Thank you, Deborah, for another great conversation.
(27:17):
And thank you to our listeners for tuning in to From QA Challenges to Innovation with
Priz.
Until next time, keep innovating.
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