Kaizen Excellence Consulting offers consulting and training services to support operational excellence through continuous improvement and lean initiatives. The document outlines a structured problem-solving approach, emphasizing root cause analysis using the '5 Whys', developing hypotheses, and proposing solutions related to inconsistent tally sheet reports and other operational inefficiencies. Various methods and tools, including statistical analysis via Minitab, are suggested for verification of hypotheses and testing of proposed solutions.

1. © 2016 Kaizen Excellence Consulting andTraining Services Company

2. © 2016 Kaizen Excellence Consulting andTraining Services Company
Kaizenex offers consulting and
training services to help your
organization achieve Operational
Excellence, supporting your
Continuous Improvement and
Lean and Six Sigma initiatives.
Elmer Buscado
Founder / Lean Advisor
Email : elmer.buscado@kaizenex.com
Tel : +639178557722
Web : www.kaizenex.com

3. © 2016 Kaizen Excellence Consulting andTraining Services Company
Step 1: Problem
Statement;
Step 2: Find the
root cause/s by
askingWhy 5
times.
Step 3: State the
practical theory
Step 4: Develop
HypothesisTest
Statement.
Step 5:Verify
Hypothesis or
Theory.
Step 6: Confirm
theTrue Cause
and reject failed
theories.
Step 7: Propose
Solution
Step 8:Assign
who will be
responsible
Step 9: Plan date
of Execution or
completion.

4. © 2016 Kaizen Excellence Consulting andTraining Services Company
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 & 9

5. © 2016 Kaizen Excellence Consulting andTraining Services Company
Problem
Statement
1st WHY 2nd Why 3rd Why 4th Why 5th Why
Root Cause
INCONSISTENT
TALLY SHEET
REPORT
NoTime to
Mark theTally
Sheet
Too Many
Orders
Too Many
Customers
Lack of Crew On rest Day
Gov’t
Regulations
Wrong Input
Do Intelligent
Guessing
Lost Track of
Count
Batch Marking
Inefficient
Crew
Some Crew
Neglect to
Mark
It is Weekend

6. © 2016 Kaizen Excellence Consulting andTraining Services Company
Problem
Statement
1st WHY 2nd Why 3rd Why 4th Why 5th Why
Root Cause
INCONSISTENT
TALLY SHEET
REPORT
Pen is not
immediately
available
Keep in the
Drawer
Common
Practice
Not Following
Procedure
NotTrained
No visual aid
available
No one Made
one
Forgot the
procedure
No visual aid
available
No one Made
one
No One is
Checking
No one is
assigned to
check
Actual Process
are inadequate
Marking is not
integrated to
serving Cycle.
Unable to
MarkTally
Sheet onTime
Form is Not
Immediately
Available
Keep in the
Folder / Nod
Defined
Location
Common
Practice

7. © 2016 Kaizen Excellence Consulting andTraining Services Company
X1: More inconsistency
generated as the demand
increases.
X3: More inconsistency
generated with less crew
X4: More Inconsistency
generated with batch marking
X5: More inconsistency
generated by some crew.
X2: More inconsistency
generated during weekends
compared to weekdays
INCONSISTENT
TALLY SHEET
REPORT
NoTime to
Mark theTally
Sheet
Too Many
Orders
Too Many
Customers
Lack of Crew On rest Day
Gov’t
Regulations
Wrong Input
Do Intelligent
Guessing
Lost Track of
Count
Batch Marking
Inefficient
Crew
Some Crew
Neglect to
Mark
Problem
Statement
1st WHY 2nd Why 3rd Why 4th Why State PracticalTheory
It is Weekend

8. © 2016 Kaizen Excellence Consulting andTraining Services Company
INCONSISTENT
TALLY SHEET
REPORT
X6: Unavailability of forms or
pen when it its needed causes
service crew to disregard
marking the tally sheets.
Pen is not
immediately
available
Keep in the
Drawer
Common
Practice
Not Following
Procedure
NotTrained
No visual aid
available
No one Made
one
X7: Absence of visual reference
will diminish recall of the
standard as time passes.
Forgot the
procedure
No visual aid
available
No one Made
one
No One is
Checking
No one is
assigned to
check
X8: No consequence of a
undesirable. behaviour promotes
undesirable behaviour to continue
Problem
Statement
1st WHY 2nd Why 3rd Why 4th Why State PracticalTheories
Actual Process
are inadequate
Marking is not
integrated to
serving Cycle.
Serving 1 cup will equate to 1 mark,
X9: Separating the marking steps in
the serving cycle will yield different
results
Unable to
MarkTally
Sheet onTime
Form is Not
Immediately
Available
Keep in the
Folder / Nod
Defined
Location
Common
Practice

9. © 2016 Kaizen Excellence Consulting andTraining Services Company
NoTime to
Mark theTally
Sheet
INCONSISTENT
TALLY SHEET
REPORT
Minitab:Conduct Regression for Diff
vs Cups Sales
Minitab:Conduct effect Screen with
X6, X7, & X9, If result is meaningful
for X6 then Perform 2 sample test
for diff by less and complete crew.
No Data:Actual
Observation/interview with service
crew.
Minitab:Conduct effect Screen with
X6, X7, & X9, If result is meaningful
for X6 then Perform 2 sample test
for diff by assigned closing crew.
Problem
Statement
Verification Method
Minitab: Conduct effect Screen with
X6, X7, & X9, If result is meaningful for
X6 then Perform 2 sample test for diff
by weekends and weekdays.
X1: More inconsistency generated as
the sales increases.
X3: More inconsistency generated
with less crew
X4: More Inconsistency generated
with batch marking
X5: More inconsistency generated
by some crew.
State PracticalTheory
X2: More inconsistency generated
during weekends compared to
weekdays
Translating to Hypothesis &Verification
Ho: Diff No Relations cups sales.
Ha: Diff has Relations cups sales
Ho: Difference has no relations with
less crew
Ha: Differences has a relations with
less crew
Ho: Difference has no relations with
assigned crew
Ha: Differences has a relations with
assigned crew.
State HypothesisTest
Ho: Weekdays has no difference with
weekends
Ha: Weekdays has difference with
weekends
Wrong Input
Inefficient
Crew

10. © 2016 Kaizen Excellence Consulting andTraining Services Company
Unable to
MarkTally
Sheet onTime
No Data:Actual Obervation:
Visit the Gemba: Observe how
forms are managed, asked the
team of the actual situations.
No Data:ActualObservation:
Visit the Gemba: Interview the
Service Crew
No Data:Actual Interview:Check
with Owner Manager of the current
approach/ process.
1st WHY Verification Method
No Data:ActualObservation and
Interview:Check the should be and
the actual process.
X6: Unavailability of forms or
pen when it its needed causes
service crew to disregard
marking the tally sheets.
X7: Absence of visual reference
will diminish recall of the
standard as time passes.
X8: No consequence of a
undesirable. behaviour promotes
undesirable behaviour to continue
State PracticalTheories
Serving 1 cup will equate to 1 mark,
X9: separating the marking steps in
the serving cycle will yield different
results
State Hypothesis test
Not Following
Procedure
Actual Process
are inadequate
INCONSISTENT
TALLY SHEET
REPORT
Problem
Statement

11. © 2016 Kaizen Excellence Consulting andTraining Services Company
Verification Method
NoTime to
Mark theTally
Sheet
INCONSISTENT
TALLY SHEET
REPORT
MAN: X1: A potential cause:
Relationship between Inconsistency
and demand is statistically
significant.
MAN: X2: A potential cause:The
mean of Weekdays(lower demand)
is significantly different form mean
Weekends.
MAN: X3: Not aTrue Cause. No
Meaningful Effect.
Analysis:
It is not conclusive to state both X1
and X2 are trueCause since both
are dependent with X3. X3 has no
meaningful effect to inconsistency.
This is base on the sample data.
Need to investigate more.
NOT CONCLUSIVE NEED MORE
DATA
METHODTrue Cause, Same with
X6 & X9 as delay in marking will let
the crew forget.
MAN: Not aTrue Cause. No
Meaningful Effect.
.
Problem
Statement
Conclusion
X1: More inconsistency generated as
the sales increases.
X3: More inconsistency generated
with less crew
X4: More Inconsistency generated
with batch marking
X5: More inconsistency generated
by some crew.
State PracticalTheory
X2: More inconsistency generated
during weekends compared to
weekdays
Conclusion
Wrong Input
Inefficient
Crew
Minitab:Conduct Regression for Diff
vs Cups Sales
Minitab:Conduct effect Screen with
X6, X7, & X9, If result is meaningful
for X6 then Perform 2 sample test
for diff by less and complete crew.
No Data:Actual
Observation/interview with service
crew.
Minitab:Conduct effect Screen with
X6, X7, & X9, If result is meaningful
for X6 then Perform 2 sample test
for diff by assigned closing crew.
Minitab: Conduct effect Screen with
X6, X7, & X9, If result is meaningful for
X6 then Perform 2 sample test for diff
by weekends and weekdays.

12. © 2016 Kaizen Excellence Consulting andTraining Services Company
Verification Method
Unable to
MarkTally
Sheet onTime
Material & Method: X6:True
Cause, as delays resulted for
Service crew to lost tracked of
count and then inputting
wrong info in the tally sheet.
Method: X7: A true cause: no
reference of the correct
procedure exist. New service
crew were not properly
trained
Method: X8: A true cause:
No feedback where given
since
1st WHY Conclusion
METHOD:True Cause, as delays
resulted for Service crew to lost
tracked of count
X6: Unavailability of forms or
pen when it its needed causes
service crew to disregard
marking the tally sheets.
X7: Absence of visual reference
will diminish recall of the
standard as time passes.
X8: No consequence of a
undesirable. behaviour promotes
undesirable behaviour to continue
State PracticalTheories
Serving 1 cup will equate to 1 mark,
X9: separating the marking steps in
the serving cycle will yield different
results
Not Following
Procedure
Actual Process
are inadequate
INCONSISTENT
TALLY SHEET
REPORT
Problem
Statement
No Data:Actual Obervation:
Visit the Gemba: Observe how
forms are managed, asked the
team the actual situations.
No Data:ActualObservation:
Visit the Gemba: Interview the
Service Crew
No Data:Actual Interview:Check
with Owner Manager, the current
approach
No Data:ActualObservation and
Interview:Check the should be and
the actual process.
Conclusion

13. © 2016 Kaizen Excellence Consulting andTraining Services Company
Proposed Solutions
INCONSISTENT
TALLY SHEET
REPORT
Elmer
Kenneth
Problem
Statement
Who
X4: More Inconsistency generated
with batch marking
State PracticalTheory
Solutions and plans –Who andWhen
Wrong Input
Discussed with crew to try new procedure and
train and implement immediately
Ask the improve to Improve the new
procedure based on experience.
Unable to
MarkTally
Sheet onTime
Elmer
Elmer / Glaiza
Elmer / Glaiza
X6: Unavailability of forms or pen
when it its needed causes service
crew to disregard marking the tally
sheets.
X7: Absence of visual reference
will diminish recall of the
standard as time passes.
X8: No consequence of a
undesirable. behaviour promotes
undesirable behaviour to continue
Serving 1 cup will equate to 1 mark,
X9: separating the marking steps in
the serving cycle will yield different
results
Not Following
Procedure
Actual Process
are inadequate
Brainstorm with crew and solicit ideas where
place tally sheet and pen to ensure it always
available.
Develop Standard of Initial Procedure, trained
and displayed it to the store.
Develop Revised standard, re-trained and
display it to the store
Modify the form to IncludeTally sheet Weekly
Checking and verifications of Sales.
Combine with X4. Same Solutions.
Leah
May 29 / Done
Jun 14 / Done
When/Status
May 29 / Done
June 7 / Done
Jun 17 / Done
JUN 17 / Done

14. © 2016 Kaizen Excellence Consulting andTraining Services Company
So the wall was finished on the twenty- fifth day of the month
Elul, in fifty- two days. And when all our enemies heard of it, all
the nations around us were afraid and fell greatly in their own
esteem, for they perceived that this work had been
accomplished with the help of our God.
NEHEMIAH 6:15-16