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Sheet 8D Report

2010 KnowWare International Inc


2253 S Oneida St Ste 3D Denver, CO 80224

www.qimacros.com/qiwizard/toyota-A3-report-template.html A3 Report 0. Determine immediate actions required (A5) 1. Establish the Team 2. Define the problem (A10) 3. Develop Interim Containment Actions (A103) 4. Identify and Verify Root Causes (RCA) (use Excel's Drawing tools to complete fishbone) Excel 97-2003 - Click on View-Toolbars-Drawing Excel 2007-2010 - Click on Insert - Shapes 5. Identify Permanent Corrective Actions (PCAs) 6. Identify and Verify the PCAs (A176) 7. Prevent Recurrence (A187) 8. Honor the Team (A230)

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Tracking Number:
Step 0 1 Establish the Team

Customer Number:
2 State the Problem 3 4

Response Due Date:


5 Corrective Actions 6 Implement Corrective Actions 7 8

Action

Planning

Containment Root Cause Plan Analysis

Prevent Recognize Recurrence Team Efforts

Planning Stage

Is an Emergency Response Action Needed? What Who When

Establish the Team

Team Goals: Team Objectives:

Department

Name

Skills

Responsibility

2A

Problem Definition

Sketch/Photo of the problem

Part Number(s):

Customer(s)

List data and documents needed

Action Plan to collect information needed

Prepare Process Flow Diagram of Problem

2B
Who

IS
Who is affected? Who first observed the problem? Reported to whom?

IS NOT
Who is not affected? Who did not find the problem?

What

What type of problem is it? What (part, lot, etc.) has the problem? What is happening with process? Physical evidence of the problem?

What does not have the problem? What could be happening but is not? What could be the problem but is not?

Why

Why is this a problem? Is the process stable?

Why is it not a problem?

Where

Where was the problem observed? Where does the problem occur?

Where could the problem be, but is not? Where else could the problem be, but is not? When could be problem have been noticed?

When

When was the problem first noticed? When has it been noticed since?

How Much Quantity of problem (PPM)? How much is it costing?

How many could have the problem but don't How big could the problem be, but is not?

How Often What is the trend? Has the problem ocurred previously?

What could the trend be, but is not?

2C

Describe the Problem

Develop Interim Containment Actions

4A

Identify and Verify Root Causes (RCA)

4A

Cause Effect Diagram


How is it made? People Materials Machine People Why did it get out? Materials Machine

Problem

Method

Environment Measurement

Method

Environment Measurement

4B

Five Why Analysis 1. Why did this happen? 2. Why? 3. Why? 4. Why? 5. Why?

4C

Action Plan What

How

Who

When

Where

Why

Identify Permanent Corrective Actions (PCAs)

Implement and Verify the PCAs

Prevent Recurrence

7A

Relicate to Similar Systems Process/Item

Who?

When?

7B

Review Documents and Systems


Document Management System Manual Manufacturing Work Instructions Inspection Work instructions Process Flow Charts Process Control Plans Design FMEA Process FMEA Gages PPAP Engineering Change Approval Who? Planned Completion Actual Completion

Honor the Team


Was the problem solving exercise effective? Has it been verified with follow-up? Yes/No Signature / Title / Date Findings

Actions
Action # Problem Containment/Corrective Action How Verified Action Who Planned Actual Status