Unlocking insights: evaluating 5Whys methodology for root cause analysis and employee problem-solving skills in 91 case studies

Purpose The 5Whys methodology is a problem-solving technique used across diverse fields to unearth the root causes of issues. Despite its widespread use, challenges persist with adequately using the tool and effectively eliminating the root cause. The purpose of this study is to assess the effectiveness of using the 5Whys technique and employees’ proficiency in problem-solving. Design/methodology/approach The research methodology uses a 91 completed 5Why case studies data set. It involves systematically retrieving 5Whys worksheets and pertinent documents, extracting data and relevant details and meticulously organizing this information within MS Excel. Subsequently, the data undergoes cleaning and transformation to achieve a structured format suitable for analysis. Finally, the data is analyzed and discussed and recommendations are provided. Findings Despite 96.7% of cases having a clear problem statement, only 57.1% quantified problem impact. Problems varied in complexity, with 53.8% classified as moderate difficulty and 25.3% having multiple root causes. However, 48.4% lacked a proper cause-and-effect sequence and 22.0% failed to identify root causes. Only 39.6% of cases eliminated root causes, with 34.1% featuring a clear problem statement, identifying root causes, implementing corrective and preventive actions and verifying their effectiveness. Employee skills were a concern, with 63.2% categorized as “Novice” and 63% completed only one 5Why problem-solving. Resolutions averaged 5.6 days, indicating the need for streamlined processes and highlighting areas for improvement in organizational capabilities. Research limitations/implications The study’s reliance on 91 production cases limits its generalizability to other environments like offices or warehouses. Practically, the findings highlight the need for improved training in the 5Whys technique, standardized root cause validation and integrating preventive actions with corrective measures. Expanding the 5Whys beyond production and complementing it with tools like fishbone diagrams can further enhance problem-solving capabilities. Originality/value This study examines the effectiveness of the 5Whys methodology and employee problem-solving skills, using a data set of 91 cases to provide new insights for enhancing problem-solving processes.