Describe the steps of a root cause analysis using the 5 Whys method after a fan failure.

• A. State the problem, ask 'Why?' repeatedly to uncover underlying causes, implement corrective actions, and verify effectiveness.
• B. Immediately replace the fan and document steps.
• C. Assign blame to operator.
• D. Create a suggestion box.

Answer: (A)

Root cause analysis using the 5 Whys is a disciplined questioning process that aims to uncover the real cause behind a failure, not just the visible symptoms. Start by clearly stating what happened with the fan—the exact failure, when it occurred, and how it affected the system or production. Then ask why this happened and use evidence to answer. Each answer becomes the next why to probe deeper, digging beyond surface issues like a stopped blade or a blown fuse to uncover underlying factors such as maintenance gaps, design limitations, or environmental conditions. Continue this chain until you reach a cause that, if addressed, would prevent recurrence.

Once the root cause is identified, implement corrective actions aimed at eliminating that cause—this could involve repairing or replacing worn components, adjusting maintenance schedules, improving lubrication or filtration, or modifying operating procedures. After implementing, verify effectiveness by monitoring the fan and related system metrics to ensure the issue does not reappear, and confirm improvements over a suitable period. Finally, document the findings, actions taken, and any changes to preventive maintenance and standard operating procedures to sustain the improvement.

Other approaches that merely replace the fan, assign blame, or rely on passive suggestions don’t address the underlying causes or foster durable prevention, which is why they aren’t appropriate for this method.