Some more real-world examples of the 5 Whys in use?

Here are several real-world examples across different industries that show how the 5 Whys technique can uncover the true root cause of a problem:

Manufacturing: Machine Downtime
Problem: A cutting machine stopped unexpectedly.

• Why? – The fuse blew due to an overload.
• Why? – The motor bearings weren’t lubricated.
• Why? – The maintenance schedule was missed.
• Why? – The planner wasn’t notified after staff changes.
• Why? – There’s no handover checklist for the maintenance team.

Root Cause: Lack of a standard handover process.
Solution: Introduced a documented checklist and updated responsibilities in the maintenance system

Office/Admin: Missed Client Deadline
Problem: Monthly report wasn’t delivered on time.

• Why? – It wasn’t finished on Friday.
• Why? – Data from finance came in late.
• Why? – They didn’t know the report was due.
• Why? – The reporting calendar wasn’t shared.
• Why? – No formal process for cross-department communication.

Root Cause: Lack of a shared reporting calendar.
Solution: Created a shared calendar with automatic reminders

Retail: Long Checkout Wait Times
Problem: Customers wait over 15 minutes during peak hours.

• Why? – Not enough cashiers available.
• Why? – Staff breaks overlap during busy periods.
• Why? – Schedule doesn’t reflect foot traffic.
• Why? – Scheduling is done manually.
• Why? – Manager isn’t using POS data for planning.

Root Cause: Manual scheduling without demand data.
Solution: Implemented POS-based scheduling and staggered breaks

Healthcare: Wrong Leg Amputated
Problem: Patient had the wrong leg amputated.

• Why? – Doctor couldn’t see the marking clearly.
• Why? – Marking was done with washable ink.
• Why? – Registrar was unaware of proper marking tools.
• Why? – No formal induction for new registrars.
• Why? – Department lacked onboarding protocols.

Root Cause: Absence of a formal induction process.
Solution: Introduced standardized onboarding and marking procedures

Personal Life: Forgotten Lunch
Problem: Child keeps forgetting lunch.

• Why? – Rushing out the door.
• Why? – Woke up late.
• Why? – Alarm didn’t go off.
• Why? – Battery died.
• Why? – No routine to check battery.

Root Cause: Lack of a Sunday night checklist.
Solution: Created a weekly reset checklist including alarm checks

These examples show how the 5 Whys can be applied to everything from industrial breakdowns to everyday hiccups. Want help crafting one for a challenge you're facing? I’d love to dig in with you.