True Causes
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Why do parts that passed inspection come back?
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anyone with the link · listed publicly · federation on
30 people · 27 ideas · 2 groups
Logic → · record
THE QUESTION

Why do parts that passed inspection come back?

The causes, deepest first. Disagreements stay on the map.

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The map
Left to right: deepest causes first; outlined green boxes are the roots. Only direct links are drawn — a link implied by a path is on the record, not in the picture. Dashed red is contested. Hover for full text.
Quotes are won on price, so cycle times are cut to the bone → The oldest machine makes the tightest-tolerance partQuotes are won on price, so cycle times are cut to the bone → Operators are paid on parts per hourParts that pass our inspection fail the customer's → The customer's returns log and ours do not matchDeburring is done by whoever is free → Parts that pass our inspection fail the customer'sRework is not counted anywhere → Quotes are won on price, so cycle times are cut to the boneThe same operator runs the same machine for years and nobody checks th → The drawing on the floor is not the revision the customer orderedCustomers changed their inspection method and never told us → Coolant is changed when it smells, not on a scheduleCustomers changed their inspection method and never told us → Operators are paid on parts per hourTool wear is judged by ear → Deburring is done by whoever is freeRework is not counted anywhereRework is not countedclusterCLUSTER 5The same operator runs the same machine for years and nobody checks thThe same operator runs thesame machine for years and…Customers changed their inspection method and never told usCustomers changed theirinspection method and neve…Tool wear is judged by earTool wear is judged by earclusterCLUSTER 3Deburring is done by whoever is freeDeburring is done bywhoever is freeCoolant is changed when it smells, not on a scheduleCoolant is changed when itclusterCLUSTER 3The drawing on the floor is not the revision the customer orderedThe drawing on the floor isnot the revision the…Quotes are won on price, so cycle times are cut to the boneQuotes are won on price, socycle times are cut to the…Parts that pass our inspection fail the customer'sParts that pass ourinspection fail the…Operators are paid on parts per hourOperators are paid on partsper hourThe oldest machine makes the tightest-tolerance partThe oldest machine makesthe tightest-tolerance partThe customer's returns log and ours do not matchThe customer's returnslog and ours do not match
How this dialogue measures
why
The indicators the method's own practitioners use to judge a dialogue's quality (Laouris & Metcalf 2024, Table 7), computed from this record so it can be compared with the hundreds of face-to-face and virtual dialogues behind their baselines. Spreadthink is the share of ideas that got at least one vote: 100% means everyone voted only for their own, and it usually settles to 25–45% once meaning has been shared. Situational complexity falls as more ideas are structured.
ideas (N)
27 usual: 50–100
with 1+ vote / 2+ votes
24 / 19
spreadthink
86.4% usual: 25–55
demosensus
13.6%
clusters (dimensions)
5
cards in a cluster
37.0%
structured / levels / links
20 / 4 / 10
situational complexity
0.45
minds moved
—
cards hidden by the steward
0
pairs contested
0
The merged map
why
Every group built its own map from its own wall; these are folded into one. The same claim raised in two groups is one item, and each connection shows how many groups found it. Where groups found opposite things, that is published as a conflict.
ROOT CAUSES
◆ fd634b4
◆ e46aacb
◆ dad034a
◆ 9984fe0
Connections several groups found (10 of 10)
Tool wear is judged by ear→Deburring is done by whoever is free1 group
Customers changed their inspection method and never told us→Coolant is changed when it smells, not on a schedule1 group
Deburring is done by whoever is free→The customer's returns log and ours do not match1 group
Rework is not counted anywhere→Quotes are won on price, so cycle times are cut to the bone1 group
Quotes are won on price, so cycle times are cut to the bone→The oldest machine makes the tightest-tolerance part1 group
Quotes are won on price, so cycle times are cut to the bone→Operators are paid on parts per hour1 group
The same operator runs the same machine for years and nobody checks th→The drawing on the floor is not the revision the customer ordered1 group
Customers changed their inspection method and never told us→Operators are paid on parts per hour1 group
Deburring is done by whoever is free→Parts that pass our inspection fail the customer's1 group
Parts that pass our inspection fail the customer's→The customer's returns log and ours do not match1 group
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