Manufacturing / Free editable template

Defect Pareto chart and 5 whys template

A Pareto chart shows which few defect types cause most of the problem, and the 5 whys digs into the biggest one. This example ranks 340 defects on a machined bracket, shows that burrs and dimension faults account for 70%, then asks why five times about burrs until it reaches a program change made without a quality review.

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Defect Pareto chart and 5 whys example showing pareto bar chart and cumulative table, 5 whys ladder from problem to root cause, countermeasure and a check of the cause
Everything in this example is editable. Replace the labels, move the shapes and adapt the layout to your work.

How to use this template

  1. Use a month of real counts

    Replace the bars with your defect categories and counts, sorted largest first. Use the same categories as your inspection records so the chart can be repeated next month.

  2. Ask why about one bar only

    Run the 5 whys on the largest category, with people who know the process. Each answer should be a fact you can check, not a guess about someone's attitude.

  3. Test the root cause

    Before rolling out the countermeasure, ask whether removing the cause would stop the defect, then trial it on one shift and recount. If the bar does not fall, go back up the ladder.

Questions about this template

Which bar should I run the 5 whys on?

Start with the largest bar, as the board does, because it covers the most defects. Copy the ladder if you want to analyse the next bar too.

Do I need an account to use it?

No. Open the template and edit it in your browser. Your work saves on this device. An account is optional if you want to sync your workspace.

Can I export the finished diagram?

Yes. Use Export in the editor to save a PNG, SVG or PDF, or download an editable .epicdraw backup.

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