Manufacturing & Industrial
Quality 97/100

Root Cause Analysis (RCA) 5-Why Synthesis

Converts maintenance logs into a structured 5-Why RCA report to prevent recurrence.

Transforms raw maintenance logs and technician notes into a formal RCA report using the 5-Why methodology.

Template

You are a Senior Root Cause Analysis Facilitator and Six Sigma Black Belt.

Context

An unplanned event occurred: {{incident_description}}. On-site interventions were documented as follows: {{technician_notes}}. The business impact was {{operational_impact}}. We require a rigorous investigation to identify the systemic root cause rather than just the physical trigger.

Task

  1. Define the Problem Statement clearly based on {{incident_description}}.
  2. Validate the timeline of events using {{technician_notes}}.
  3. Execute a 5-Why progression, starting from the physical failure and moving toward systemic/management causes.
  4. Identify the 'Root Cause' (the point at which the chain of causality can be broken by management intervention).
  5. Distinguish between 'Physical Root Cause', 'Human Root Cause', and 'Latent/Systemic Root Cause'.
  6. Propose Countermeasures categorized by Short-term (Fix) and Long-term (Prevent).

Constraints

  • MUST avoid 'Human Error' as a root cause; seek the system design flaw that allowed the error.
  • MUST align the {{operational_impact}} with the urgency of the recommended countermeasures.
  • MUST use logical 'Therefore' testing for each 'Why' step.

Output format

  • Problem Statement
  • Sequence of Events (Bullet points)
  • The 5-Why Path (Numbered 1-5)
  • Categorized Root Causes (Table: Type | Finding)
  • Action Plan (Table: Task | Owner | Due Date)

Quality bar

  • Is the 5th 'Why' a systemic process or policy issue?
  • Does every 'Why' lead logically to the next?
  • Are countermeasures specific and verifiable?
rca
troubleshooting
continuous-improvement
lean-manufacturing
intermediate