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8D Investigation Report
Revision : 05/06/2016

D0. Background D1 - Team

Date Customer Ref Internal Ref Rank A. Ardan

A
Customer D. Martin
Customer name F. Rodin
Contact details 546-09 2009-056 K.Benamou
Vehicle E. Tobin
Plant / Workshop

D2 - Describe the problem

i. Customer description iii. Scope
Known concern ? Y/N
Other models/customers affected? Y/N
ii. Internal description
What? iv. Picture, Sketch
When?
Who? Where? How many?
How?
Why? NG
µ Attachements : 0

D3 - Containment Actions
Location Affected Total Sorted NG Progress Visualization
S Incoming inspection Y/N 20 10 5
O Internal stocks Y/N
R Manufacturing process Y/N
T
Finished Stocks Y/N
I
N Customer stock Y/N
G Customer side of line Y/N
Customer yards Y/N
Overall 20 10 5
Item Lead Location Date Quantity Comments
C
O
N
T
A
I
N
'

D4 - Identify Root Cause, D5 - Implement countermeasures, D6 - Monitor

Item Root Cause (Cf. to Attachment) Counter Measure Action Lead Due Actual

D6 - Reccurence Prevention
Items Action Lead Due Statu
DFMEA
PFMEA
Control Plan
Work Instructions
Measurement
Others
D7 - Congratulate the team Case closure follow-up
Date : Date of closure :
Lead : Agreed PPM / Cost:
Other agreements :
Ishikawa

[1] Material [2] Methods [3] Machines

1.1 Plastic cover material NG 2.1 Screwing order NOK 3.1 Screwdriver torque deviation
1.2 Screw material NG 2.2 No torque control 3.2 Injection parameters deviation
u 1.3 Screw dimension NG 2.3 Plastic injection param. NG 3.3 Screwing order not as planed
u 1.4 Plastic cover dimension NG 3.4 Poka Yoke not working

Missed operation 4.1 Deformation due to temp. 5.1 Torque wrench NG 6.1
Did not follow work instruction 4.2 Torque decrease due temp. 5.2
Cross-thread when screwing 4.3 Torque decrease due humidity 5.3

[4] Manpower [5] Environment [6] Measurement

Confirmation of ishikawa items

# Potential Cause Standard Actual Judg. Link Status Reference / Evidence
1.1 Plastic cover material NG ABS PC ABS PC OK No Closed Lab report #059
1.2 Screw material NG Steel XX Steel XX OK TBX
1.3 Screw dimension NG 5.0 +/- 0.1 5.08 OK TBC Med. Prior Tridim report #2010-089
30 +/- 0.2 30.03 OK No Low Prior. Tridim report #2010-090
1.4 Plastic cover dimension NG 4.1 +/- 0.2 4.5 NG Yes High Prior. Tridim report #2010-089
Confirmed screwing order cannot ca
2.1 Screwing order NOK 1>2>3>4 1>2>3>4 OK No Closed such issue

2.2 No torque control

2.3 Plastic injection param. NG
3.1 Screwdriver torque deviation
3.2 Injection parameters deviation
3.3 Screwing order not as planed
3.4 Poka Yoke not working PY should work PY is OK OK No Closed Confirmed PY is OK

4.1 Missed operation

4.2 Did not follow work instruction
4.3 Cross-thread when screwing
5.1 Deformation due to temp.
5.2 Torque decrease due temp.
5.3 Torque decrease due humidity
6.1 Torque wrench NG

Additional supporting materials

 D1 - Team
4567
4568
4569
4570
4571

Progress Visualization

Comments

Check

Status
w-up

Reference / Evidence
Lab report #059

Tridim report #2010-089

Tridim report #2010-090
Tridim report #2010-089
Confirmed screwing order cannot cause
such issue

Confirmed PY is OK
Mold 5W1H Problem Definition Worksheet
Team
INJ Report problem.
Tool Check the mold can repair at internal or not.
ENG Check and report problem to customer/mold maker if any requested.
QC Check the status after repaired
5W2H
What hapenned? What is the problem ?
Chuyện gì đã xảy ra? Vấn đề là gì?

What product name/code?

Tên tên sản phẩm/mã sản phẩm?
What?

What material was being used?

Tên nhựa?

What will happen if we don’t solve the problem?

Chuyện gì sẽ xảy ra nếu vấn đề không được giải quyết?

When did it happen (date / time/shift) ?

When? Vấn đề xảy ra khi nào (Ngày/ giờ/ca)?

Who faced the problem ?

Người trực tiếp gặp lỗi này?

Who reported the problem ?

Who? Người báo cáo vấn đề này?

Who is the customer ?

Khách hàng là ai?

Where did it happen (machine number)?

Where? Vấn đề xảy ra ở đâu (số máy ép)?

Why is it a problem ?
Lý do vì sao xảy ra lỗi này?

Why?

How did it happen ? (step by step explanation)

Vấn đề xảy ra như thế nào? (giải thích từng bước)

How?
Pareto
Item Deffect Rate Cumulative
Item 1 11% 11% Pareto
Item 2 8% 19% 12%
84%
Item 3 7% 26% 10% 77%
81%
73%
Item 4 7.0% 33% 65%
69%
8% 61%
Item 5 6.0% 39% 51%
56%
45%
Item 6 6.0% 45% 6% 39%
33%
Item 7 5.5% 51% 4% 26%
Item 8 5.0% 56% 19%
2% 11%
Item 9 5.0% 61%
11% 8% 7% 7% 6% 6% 6% 5% 5% 5% 4% 4% 4% 4% 4%
Item 10 4.5% 65% 0%

Item 1

Item 2

Item 4

Item 5

Item 6

Item 8

Item 9

Item 10

Item 11

Item 12

Item 13

Item 14

Item 15
Item 3

Item 7
Item 11 4.0% 69%
Item 12 4.0% 73%
Item 13 3.8% 77%
Item 14 3.8% 81% Pareto
Item 15 3.8% 84% 12%
Item 16 3.5% 88% 81%
84
10% 77%
73%
Item 17 3.5% 91% 65%
69%
8% 61%
Item 18 2.5% 94% 56%
51%
Item 19 2.0% 96% 6% 39%
45%
33%
Item 20 1.5% 97% 4% 26%
Item 21 1.5% 99% 11%
19%
2%
Item 22 1.0% 100% 11% 8% 7% 7% 6% 6% 6% 5% 5% 5% 4% 4% 4% 4% 4%
0%
Item 1

Item 2

Item 3

Item 4

Item 5

Item 6

Item 7

Item 8

Item 9

Item 12

Item 13

Item 14
Item 10

Item 11
Pareto
12%
84
81%
10% 77%
73%
69%
65%
8% 61%
56%
51%
45%
6% 39%
33%
4% 26%
19%
11%
2%
11% 8% 7% 7% 6% 6% 6% 5% 5% 5% 4% 4% 4% 4% 4%
0%
Item 1

Item 2

Item 3

Item 4

Item 12

Item 13

Item 14
Item 5

Item 6

Item 7

Item 8

Item 9

Item 10

Item 11
 Pareto
100%
96% 97% 99%
91% 94% 100%
88%
84% 90%
81%
77%
69%
73% 80%
65% 70%
61%
60%
50%
40%
30%
20%
10%
5% 5% 4% 4% 4% 4% 4% 4% 4% 3% 2% 2% 2% 1%
0%
Item 9

Item 10

Item 11

Item 12

Item 13

Item 14

Item 15

Item 17

Item 18

Item 20

Item 21

Item 22
Item 16

Item 19

Pareto
100%
96% 97% 99%
100% 91% 94%
88%
84%
90% 81%
77%
73% 80%
69%
65%
61% 70%
60%
50%
40%
30%
20%
5% 5% 4% 4% 4% 4% 4% 4% 4% 3% 2% 2% 2% 1% 10%
0%
Item 9

Item 12

Item 13

Item 14

Item 15

Item 16

Item 17

Item 18
Item 10

Item 11

Item 19

Item 20

Item 21

Item 22

Pareto
100%
96% 97% 99%
100% 91% 94%
88%
84%
77%
90% 81%
73% 80%
69%
65%
61% 70%
60%
50%
40%
30%
20%
5% 5% 4% 4% 4% 4% 4% 4% 4% 3% 2% 2% 2% 1% 10%
0%
Item 12

Item 13

Item 14

Item 15

Item 16

Item 17

Item 18
Item 9

Item 10

Item 11

Item 19

Item 20

Item 21

Item 22
5 Why's
Ishikawa Diagram (Fishbone Diagram)

Man Material Methods

Text Text
Text Text Text
Text Text
Text Text Text
Text Text

Machine Environment Measurement

 Methods

Concern

Text
Text Text

Text Text

surement
Ishikawa Diagram (Fishbone Diagram)

[1] Material [2] Methods

.1 Plastic cover material NG .1 Screwing order NOK
.2 Screw material NG .2 No torque control
u .3 Screw dimension NG .3 Plastic injection param. NG
u .4 Plastic cover dimension NG

Missed operation .1 Deformation due to temp. .1

Did not follow work instruction .2 Torque decrease due temp. .2
Cross-thread when screwing .3 Torque decrease due humidity .3

[4] Manpower [5] Environment

 [3] Machines
.1 Screwdriver torque deviation
.2 Injection parameters deviation
m. NG .3 Screwing order not as planed
.4 Poka Yoke not working

Plastic cover
Plastic cover
Torque wrench NG loose
loose

[6] Measurement
FTA : Failure Tree Analysis
FTA : Failure Tree Analysis