WHO IS EFFECTED BY THE PROBLEM? Date Open: 8D No.

:
Company: Initial Response:
Customer
Complaint No.:
Address: Target Close Date:
Location: Revision Date(s):
Part No./Code 8D Initiator:
Product Name: 8D Initiator's Spvr:
Actual Close Date:
Champion:
Team Leader:
Team Members:
%
Effective:
Target
Date:
Actual
Date:
Target
Date:
Actual
Date:
Target
Date:
Actual
Date:
Check boxes that apply:
WGCPF-001 page 1 of 9 Rev. 5 18-Nov-03
D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE:
Mistake Proofing: How are you going to ensure it can't happen again?
Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location.
If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, Ontario
D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):
THE WOODBRIDGE GROUP - 8D Response Report
D1 TEAM MEMBER NAMES/TITLES: D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)
D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.
HOW WILL YOU VALIDATE THE PCA?
HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:
D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):
HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:
HOW DID YOU VERIFY THE ROOT CAUSE(S)?
% Effective: D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):
D4 DEFINE AND VERIFY ROOT CAUSE(S):
HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?
% Contribution:
INTERNAL or EXTERNAL
Control Plan FMEA Flowchart Proc./Work Instr. Add to Internal Audit
Instructions
WHO IS EFFECTED BY THE PROBLEM? Date Open: 8D No.:
Company: Initial Response:
Customer
Complaint No.:
Address: Target Close Date:
Location: Revision Date(s):
Part No./Code 8D Initiator:
Product Name: 8D Initiator's Spvr:
Actual Close Date:
Champion:
Team Leader:
Team Members:
%
Effective:
Target
Date:
Actual
Date:
Target
Date:
Actual
Date:
Target
Date:
Actual
Date:
HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:
Check boxes that apply:
WGCPF-001 page 2 of 9 Rev. 5 18-Nov-03
Modify the management systems, operating systems, practices and procedures to prevent recurrence of this and all similar problems.
(What is the "Escape Root Cause"? What in your system allowed this problem or any problem from leaving your plant and not getting
detected?). Choose on-going controls, including mistake proofing methodology, such as the use of process or design features to prevent
manufacture of nonconforming product/service. Review control plans, FMEA's, flowcharts, etc. for revisions.
LINK TO PROBLEM SOLVING WORKSHEET - PROBLEM DESCRIPTION
D4 DEFINE AND VERIFY ROOT CAUSE(S):
LINK TO DECISION MAKING WORKSHEET & RISK ANALYSIS
How
effective is
your ICA so
the customer
does not see
the
problem?
How can you make the problem come and go - prove it - test results - document it.
HOW DID YOU VERIFY THE ROOT CAUSE(S)?
D1 TEAM MEMBER NAMES/TITLES: D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)
% Contribution:
How can you make the problem come and go - prove it - test results - document it.
LINK TO PLANING AND PROBLEM PREVENTION WORKSHEET
% Effective:
Define and implement the best permanent corrective actions. Include the removal of the ICA. Choose on-going controls to ensure the
root cause is eliminated. Once in production, monitor and evaluate the long-term effects and implement contingency actions, if
necessary. This step describes HOW you will do it.
LINK TO PROBLEM SOLVING WORKSHEET - ROOT CAUSE WITH THEORY TESTING
Identify all potential causes (due to a change) which could explain why the problem occurred. Isolate and verify the Root Cause by testing
each potential cause against the problem description and test data (does it explain the IS,IS/NOT'S in D2?). Identify alternative corrective
actions to eliminate root cause.
Through pre-production test programs, quantitatively confirm that the selected corrective actions will resolve the problems for the
customer and will not cause undesirable side effects. Define contingency action, if necessary based on the risk assessments. This step
describes WHAT you will do.
Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location.
If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, Ontario
What % of the
problem is caused by
the root cause(s)
(must have 100%
total)
How effective is your
PCA so the problem is
cured not masked?
(must have 100%
total)
D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE:
Mistake Proofing: How are you going to ensure it can't happen again?
HOW WILL YOU VALIDATE THE PCA?
Use validation tools for long term results: Trend - Pareto - Paynter, etc.
D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):
HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:
How can you make the problem come and go - prove it - test results - document it.
D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.
D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):
Note: Develop Action Plan (can use worksheets to help brainstorm)
HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?
What are the symptoms that the customer is seeing? Specify the internal/external customer
problems by identifying in quantifiable terms who, what, when, where, why, how, how many (5W2H)
of the problem.
Define and implement containment actions to isolate the problem from any internal/external customer until permanent
corrective action is available. Verify the effectiveness of the action. The ICA is a type of 'Band-Aid' used to protect the
customer until the root cause is determined and the permanent correction can be implemented.
D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):
THE WOODBRIDGE GROUP - 8D Response Report
INTERNAL or EXTERNAL
Control Plan FMEA Flowchart Proc./Work Instr. Add to Internal Audit
WHO IS EFFECTED BY THE PROBLEM? Date Open: 8D No.:
Company: Example Customer Initial Response:
Address: 1234 Somewhere St. Target Close Date:
Location: Mytowne, MI Revision Date(s):
Part No./Code 26003 8D Initiator:
Product Name: Front Seat Back Cushion Supervisor:
Actual Close Date:
Champion: Al Bossman
Team Leader: Joe Smith
Team Members:
%
Effective:
Target
Date:
Actual
Date:
Target
Date:
Actual
Date:
Target
Date:
Actual
Date:
Check boxes that apply:
WGCPF-001 page 3 of 9 Rev. 5 18-Nov-13
D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE:
Mistake Proofing: How are you going to ensure it can't happen again?
D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.
Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location.
If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, Ontario
Add pour pattern to FMEA. Statistically monitor cycles/pours to determine when auto vents should be changed
(prior to clog). Add auto vent check to PM program and revised work instruction BRPMW-018
HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:
05-Jun-03 05-Jun-03
D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):
1. Moved pour head 10 mm from the parting line (was 35 mm) and start in front and end in back. 2. Replaced
auto vent with new one.
30-May-03
1. Change robot pour pattern 2. Change auto vent.
100% HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:
Monitored 30 pours for splash and checked auto vent after 30th pour for no clogs.
29-May-03 HOW WILL YOU VALIDATE THE PCA?
Paynter chart 100% on-line inspection first 3 shipments.
Attribute study from management dock audits on first 3 shipments to Example Customer (np-chart 10 pieces
every hour at end of line).
D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA): % Effective:
1. 70%
2. 30%
HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?
Paynter Chart
Attribute p-chart (0 found) by management audit.
D4 DEFINE AND VERIFY ROOT CAUSE(S): % Contribution:
D1 TEAM MEMBER NAMES/TITLES: D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)
Can make voids come and go by altering pour pattern without splash and with splash. New auto vents produce
no clogs thus no voids.
Front Seat Back Cushions 26003 have voids.
June returns from Example Customer exceeded 450 TPPM.
Of the 31 pieces returned, 26 pieces were rejected for voids (84% of returns).
TPPM calculation = 31 rejections/35,000 pieces shipped x 1,000,000 = 886 TPPM
Les Shippet, Stan Tistics, Ima
Goodguy
D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):
Review all material in-house and at Example Customer. Post "Alert" in plant and communicate
defect to all management personnel. 100% inspection area set up in cell 1 for each shift.
Management audit in warehouse and hand initial each label.
100% 26-May-03 26-May-03
1. Foam splashing on seal. 2. Malfunctioning auto vent: Cleaned after demold, proper air pressure and cycling
is occurring but still malfunctioning by clogging.
HOW DID YOU VERIFY THE ROOT CAUSE(S)?
Joe Smith
Al Bossman
6/9/2003
THE WOODBRIDGE GROUP - 8D Response Report
5/26/2003
6/10/2003
5/30/03, 6/5/03
5/25/2003 BR-03-001
INTERNAL or EXTERNAL
Control Plan FMEA Flowchart Proc./Work Instr. Add to Internal Audit
0
1. Operational
Definition
What's wrong with
what? Why?
WHAT
Object
Defect
WHERE
Seen on object
Seen
geographically
WHEN
First seen
When else seen
When seen in
process (life cycle)
HOW BIG
How many objects
have the defect?
How many defects
per object?
What is the trend?
Updated By: Update Date: Update #:
WGCPF-001 page 4 of 9 Rev. 5 18-Nov-03
PROBLEM DESCRIPTION (D2)
(Type in D2 here)
2. Description
of Problem
IS IS NOT GET INFO ON
0
4. Possible Causes
3a. Differences 3b. Changes Date List Change-How Theories
WHAT
Object
0 0
A
Defect
0 0
B
WHERE
Seen on object
0 0
C
Seen
geographically
0 0
D
WHEN
First seen
0 0
E
When else seen
0 0
F
When seen in
process (life cycle)
0 0
G
HOW BIG
How many objects
have the defect?
0 0
5. Test causes for probability (+, -, ?) Page 2
Does it explain Is/Is Not fact?
How many defects
per object?
0 0
What is the trend?
0 0
Updated By: Update Date: Update #:
WGCPF-001 page 5 of 9 Rev. 5 18-Nov-03
6. Steps to verify Root Cause?
(make the problem come and go)
1. Operational Definition
What's wrong with what? Why?
PROBLEM SOLVING WORKSHEET (D4)
(Type in D2 here) (Type in D2 here)
2. Description
of Problem
IS IS NOT
3. Deductions About Facts and Other Information
0
TESTING POSSIBLE CAUSES (D4 Continued)
C
h
a
n
g
e
-
H
o
w

T
h
e
o
r
i
e
s
0 0 0 0 0 0 0
"IS's" A B C D E F G
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Comments/
Follow-Up
Items
Updated By: Update Date: Update #:
WGCPF-001 page 6 of 9 Rev. 5 18-Nov-03
0
(1) END RESULT:
Y/N Y/N Y/N Y/N
WANTS: flexible limits, subjective, realistic
(3) How
Important
(1-10)
INFO
(5) How
Good
(0-10) Score
INFO
(5) How
Good
(0-10) Score
INFO
(5) How
Good
(0-10) Score
INFO
(5) How
Good
(0-10) Score
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0
0
Update Date:
WGCPF-001 page 7 of 9 Rev. 5 18-Nov-03
DECISION MAKING WORKSHEET (D3 & D5)
(2) CRITERIA:
(4) CHOICES AVAILABLE - (INNOVATE)
A B C D
(5) INFO GIVENS: (mandatory, measurable, realistic) (5) INFO (5) INFO (5) INFO
0 0 0
Update Rev #:
0 Relative MERIT (total score)
Updated By:
0
(6) RISK ANALYSIS: State your risks in "IFTHEN" terms. "If we do this, what might happen, contrary to our interest?"
1st Choice P S 2nd Choice P S 3rd Choice P S
3. UNIVERSAL
Basic Sources of Trouble:
People
Organization
External Influences
Facilities
Equipment
Ideas
Policies
Processes
Materials
Money - Economics
Capacity
Quality
Timing
Personal Influence
"SERIOUSNESS" No. 10 means rejection if "PROBABILITY" is certain (10 x 10). P = Probability (1-10) S = Severity (1-10)
Update Date: Update Rev #:
WGCPF-001 page 8 of 9 Rev. 5 18-Nov-03
7. Make the Final Balanced Choice
DECISION MAKING WORKSHEET - RISK ANALYSIS (D3 & D5)
Investigate one choice at a time
1. RISK
What characteristics of
this choice may fail to
satisfy the GIVENS?
Updated By:
2. RISK
What features or
characteristics of this
choice compromise or
threaten an important
WANT?
Use the checklist to stimulate ideas.
0
P S
Revised By: Revision #:
WGCPF-001 page 9 of 9 Rev. 5 18-Nov-03
Revision Date:
6. PREVENTION ACTIONS 7. PROTECTION ACTIONS 8. CUES (DATE OR EVENT)
PLANNING AND PROBLEM PREVENTION WORKSHEET (D6)
1. OBJECTIVE OF THE PLAN (Goal with timing):
9. WHO 2. KEY STEPS 3. POTENTIAL PROBLEMS
4. PRIORITY
5. POSSIBLE CAUSES