2. P roblem S olving I nnovator Solving Tomorrows Problems Today The 1 st Why can be formed once the Team has Brainstormed for Potential Causes The 1 st Why can be formed once the Team has Brainstormed for Potential Causes 1 st Why / Function Development 1 st Why / Function Development 1 st Why / Function Examples 1 st Why / Function Examples 1 st Why / Function & FMEA 1 st Why / Function & FMEA 1 st Why / Function & Cause & Effect (Fishbone) 1 st Why / Function & Cause & Effect (Fishbone)

3. COVER PAGE

4. D4 - Developing the 1 st Why / Function …Options Option 1: Use the Affinity Diagram to naturally group ideas, Example VALVE MANUFACTURING 1st Why/Function Development OR Option 2: Use the Product (Assembly) Components, Example VALVE LEAKS POSTURE SPINAL COLUMNMUSCLES NERVES ASSOCIATED ORGANS Option 5: Use any other logical method or Sequence, Example BACK ACHES OR Option 4: Use a Process Orientated (Process Flow ) approach, Example COOKING OR RAW MATERIAL MACHININGTAPPING ASSEMBLY/ TEST DESIGN/ APPLICATION PREPARE INGREDIENTSCOOK/BAKE FOOD PLATE UP EAT FOODBUY INGREDIENTS Option 3: Use a Circumstantial Approach, Example TEAM DISAGREEMENT OR DEADLINESFRUSTRATION INCONSIDERATION PERSONALITYCOMMUNICATION WASHER VALVE BODY TEST/ ASSEMBLY ADAPTORFLUID & FITMENT

5. Applicable points from the Brainstorming Seal Surface Deteriorates Wrong Washer Damaged face of Valve I Adaptor damaged thread Missing Washer Vibration of Valve Thread Pitch Operational Use RAW MATERIAL MACHININGTAPPING ASSEMBLY/ TEST DESIGN/ APPLICATION WASHER VALVE BODYTEST/ASSEMBLYADAPTORFLUID & FITMENT RAW MATERIAL MACHININGTAPPING ASSEMBLY/ TEST DESIGN/ APPLICATION Components of Valve Washer Valve Body Test/Assembly Adaptor Fluid & Fitment D4 - Developing the 1 st Why / Function …Options Option 1: Use the Affinity Diagram to naturally group ideas, Example VALVE MANUFACTURING D4 - Developing the 1 st Why / Function …Options Option 2: Use the Product (assembly) Components, Example VALVE LEAKS 1st Why/Function Examples

6. 1 st Why = the Function The Function describes each Process Step in a Process Select which Possible 1 st Why Function you would like to Investigate 2 nd Why 3 rd Why 4 th Why 5 th Why RAW MATERIAL TAPPING ASSEMBLY/ TEST DESIGN/ APPLICATION MACHINING 1 st Why / Functions & FMEA 1st Why Functions

7. The 1 st Why will be forwarded to the 1 st Arms of the Cause & Effect Diagram Automatic Population of C&E (Fishbone)

8. P roblem S olving I nnovator Solving Tomorrows Problems Today This completes the D4 1 st Why Now start the D4 2 nd Why