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5+ Whys

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The 5 Whys tool is a commonly used method for Root Cause Analysis. It is often seen as a simple process of asking the question ‘Why?’ five times to uncover the underlying reason behind a problem. However, this perception is not entirely accurate. The 5 Whys is actually a powerful creative thinking tool designed for thorough problem analysis and resolution.

Here, we present a modified version of the 5 Whys tool, incorporating concepts developed by PRIZ Guru Inc. This modified version offers the following key features:

  • Comprehensive Problem Analysis: To facilitate a more detailed analysis, we introduce the 5+ Whys tool, which encourages an extended sequence of ‘Whys’ to dig deeper into the issue.
  • Root Cause as a Source of Solutions: While identifying the Fundamental Reason of the Problem (FRP) is important, it may not always lead to problem resolution. We emphasize that a Root Cause can also be a source of solutions, with each step potentially contributing to a solution.
  • Machine Assistance: Incorporating machine assistance can be valuable during the search for root causes and the creation of solutions, streamlining the process.
  • Effective Ideas and Solutions Management: The 5+Whys method places a strong emphasis on ranking ideas and solutions, as well as making informed decisions, ensuring a comprehensive approach to problem-solving.

What can you gain from using 5+Whys?

The 5+Whys technique is a valuable tool for creative thinking that helps break free from psychological inertia. It redirects our focus towards a logical analysis of sequential causes and effects. By utilizing this tool, we can achieve a deeper understanding of systems and generate effective solutions. Here are some notable benefits associated with using the 5+Whys technique:

  • Improve your understanding of the system by identifying its most problematic aspects.
  • Shift from guesswork to generating reasoned solutions and ideas.
  • Establish pathways for future system development.
  • Cultivate effective problem-solving within your team.

When should you use the 5+Whys tool?

The 5+Whys tool is highly effective in providing quick responses and is invaluable in various scenarios. It is especially useful for addressing unexpected parameter deviations (excursions) and analyzing and resolving chronic problems. Some notable applications include:

  • Dealing with unforeseen deviation.
  • Improving Key Performance Indicator (KPI) metrics for chronic issues.
  • Promoting innovation and process optimization.
  • Supporting continuous process and product improvement.

Furthermore, the 5+Whys thinking tool is versatile and can be applied in numerous other contexts to harness its creative problem-solving potential.

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Showcasing Successful Projects

Microelectronics

SiO2 thin film creation in Diffusion furnace - Process Functional Modeling

The process is related to microelectronics - microchip manufacturing.The purpose of the process is to create a SiO2 layer on the surface of a Si wafer. Equipment: Vertical furnace to heat the wafers in the Q2 atmosphere and perform oxidation on the wafer surface. Process: The oxidation occurs on the front side and on the back side of the wafer Requirements: Create a SiO2 thin layer with a certain thickness and low sigma - low standard deviation of the thickness between the wafers and within the waferFailure: Wafers from the lower zone have higher thickness and significantly higher within wafer sigma (standard deviation of the thickness within the wafer)

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Dr. Anatoly Agulyansky
Microelectronics

Wafer cleaning issues at the wet process

Wet cleaning is widely used in microchip manufacturing. Single wafer equipment is working as follows. A wafer rotates, and chemistry is poured from a movable nozzle. Water rinsing is performed at the end of the process. Loading of a new batch of the chemistry resulted in excursion - a strongly increased amount of defects was observed on the wafer after the processing. The project is dedicated to the failure analysis and creation of innovative solutions.

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Dr. Anatoly Agulyansky
Microelectronics

Optimizing IC Interconnection: A Functional Approach to Innovation (Stay updated on the project's progress)

Semiconductor devices are becoming more complex and expensive. But what exactly are we paying for when we buy a computer, cellphone, or any device containing a microchip? It’s not for radically new functions—the core components remain the same: transistors and interconnections. According to Moore’s law, transistors are getting smaller, with more interconnection layers added, making the manufacturing process longer and more costly.In reality, we’re paying for the inability of engineers to efficiently solve engineering challenges.This project leverages System Functional Modeling (SFM) to analyze the IC interconnection layer and Process Functional Modeling (PFM) to evaluate its manufacturing process. These analyses aim to deepen our understanding of both the device and the production process, generating innovative solutions for cost reduction and improved efficiency.

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Dr Anatoly Agulyansky
Mechanics

Functional Modeling of a Vacuum Cleaner: A Pathway to Innovation

This project showcases how functional modeling can drive innovation by analyzing and simulating various versions of a vacuum cleaner. By studying the functional model, you will experience firsthand how the Functional Modeling creative thinking tool helps identify opportunities for improvement and generate innovative ideas for the next generation of products.Through this example, you’ll learn how to dissect the functionality of a vacuum cleaner, revealing ways to enhance its performance, efficiency, and user experience—ultimately paving the way for future innovations.

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Dr. Anatoly Agulyansky
Microelectronics

Wafer breakage at flash heating

Flash heating of a wafer is widely used in microchip manufacturing. The purpose of the process is to prevent the diffusion of ions and atoms. During the flash process, a wafer breakage occurs. The project's purpose is to learn and understand the mechanism of the wafer breakage and propose the solutions to prevent the wafer breakage

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מניעת עיבוי על העדשות - רוני עוז ותומר קליין

?כיצד נוכל למנוע הצטברות של אדים על גבי העדשה בתנאי סביבה שונים כדי לשפר את הראייה והבטיחות

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Roni Oz
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Recycling waste of solar panels.students: Alaa & saed

Excited to share our latest project at Ben-Gurion University of the Negev! 🚀 We tackled the pressing issue of solar panel waste and explored innovative recycling solutions to make solar energy truly sustainable.Key insights:Solar panel waste could hit 78 million metric tons by 2050. Only 10% of panels are currently recycled in the EU. Our project highlights the need for efficient recycling technologies, better regulations, and economic incentives to drive sustainable practices.Let’s work together for a greener future! 🌱

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Saed Hasson
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Metal to Metal-Halide Perovskites. By Layla Khateeb, Aviv Dahari.

This project aims to develop an efficient and reproducible method for synthesizing perovskites from metals with halides. The focus will be on addressing material synthesis challenges, ensuring scalability from laboratory to industrial production, optimizing the physical and chemical properties, and minimizing the environmental impact.

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Aviv Dahari

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