8-D Principals for Problem Solving Supplier Approvals :(must be approved by Supplier Plant, Quality and Production Manager

Supplier Approvals :(must be approved by Supplier Plant, Quality and Production Manager prior to close by Autoliv)

Note: Supplier to complete all cells that are colored yellow. No Yellow cell should be left blank, if needed mark "N/A".
Summary Page is pulled from the data provided in the Yellow blanks, do not alter the Summary Page.
Plant Manager Date

NCM Number 2014 1527 Supplier Name and ID Arcosa Quality Manager Date

Date Issued 12-9-14 Production Manager Date

PN(s): 629317000E
PROBLEM RANK CHAR. ID (CHECK BOX) PROBLEM STATEMENT
CC X SC 8-D Completion Date:
C Duplicate PKG ID-UNIT on box
CIP NA

2a PROBLEM DEFINITION 2b PROBLEM DEFINITION (CLARIFYING FACTS) 3 IMPLEMENT CONTAINMENT ACTIONS

(PROBLEM SIDE) ( Attach Photos to Worksheet 3) (See Containment Checklist, Worksheet 4) Percentage
A. WHO: Autoliv Part Analysis: Supplier Sort Qty 0 Defects Qty 0 #DIV/0!
B. WHAT: Duplicate PKG ID-UNIT on box The ID number is created automatically by a system that indicates; YYYYMMDDXX, Autoliv Sort Qty 236 Defects Qty 236 100.00%
X: Consecutive number (the Consecutive number start with each New Lot)
C. WHERE AOA Customer Sort Qty 0 Defects Qty 0 #DIV/0!
D. WHEN: 12/9/2014
E. WHY: Requirement was not reviewed Process Analysis: Totals: 236 236 100.00%
F. HOW: Requirement was not reviewed Customer requirement was not reviewed (Data = Unique Package ID)
G. QUANTITY: 1
4d IDENTIFY ROOT CAUSE
4a Why analysis (Circle causes to be countermeasured in all three categories) Root causes from 4a-4c
Worksheet 2. 8-D Backside are recommended tools to facilitate Root Cause Analysis.(4b and
4c)
Label software was programing incorrectly

WHY(1) WHY(2) WHY(3) WHY(4) WHY(5) The root cause for this specific occurrence is…
Label software was programing incorrectly
What is the immediate cause of the <--- What is the cause of the <--- What is the cause of the <--- What is the cause of the <--- What is the cause of the
problem? previous cause? previous cause? previous cause? previous cause? The root cause for non-detection is…
Lack training in procedure of PPAP to Engineering and Quality department.
The root cause for the system failure is…
(Use this area to visually document before and after conditions) ie, process, tooling, inspection
SPECIFIC

Document Control BEFORE

Assistance not verified AFTER
The route for this assy
both screen in ENOVIA
was a requirement
to validate the correct
drawing

Why was the problem not detected <--- What is the cause of the <--- What is the cause of the <--- What is the cause of the <--- What is the cause of the
and contained at the source? previous cause? previous cause? previous cause? previous cause?
DETECTION
(Protect)

What in the current system allowed <--- What is the cause of the <--- What is the cause of the <--- What is the cause of the <--- What is the cause of the
the problem to occurr? previous cause? previous cause? previous cause? previous cause?
SYSTEMIC
(Prevent)

5 CORRECTIVE COUNTERMEASURE(S) 6 CONFIRM COUNTERMEASURE(S) 7 PREVENT RECURRENCE

Identify Temporary & Permanent, Addition of Error-Proofing Verfiy the effectiveness of the Yokoten Worksheet
Responsibility and Date ( from 4D ) countermeasure record verfication date. must be completed
Specific CA Update label software properly with the configuration IIIIIILLBB. Comp. Date Specific: 12/12/14
Where: I:Invoice number, L:Line and B:Box number Detection: 12/12/14
The Invoice number is unique therefore the PKG ID Unit can't be duplicate. Completion Date Systematic: 1/9/2015 8 CONGRATULATE TEAM
11-Dec-14
22 boxes
Detection CA Update label software properly with the configuration IIIIIILLBB. Comp. Date Quantity Verifed
Where: I:Invoice number, L:Line and B:Box number
The Invoice number is unique therefore the PKG ID Unit can't be duplicate.
11-Dec-14 0
Defects Found Note: NCM Timeline - Supplier Requirement (See NCM)
Systemic CA Training to all departments involved into the PPAP procedure. (P20-0104). Comp. Date Emergency Response Acknowledgement Within 2 hours
Short Term Action Plan 8D Sections 1-3 Within 24 hours
6-Jan-15
Long Term Action Plan 8D Sections 4-5 Within 7 days
Closed 8-D Report Plan 8D Sections 6-8 Within 28 days
Rev 007 November 11, 2014
 Supplier Approvals :(must be approved by Supplier Plant, Quality and Production Manager prior to close by Autoliv)
These tools are optional.

4b Identify Root Cause (Brainstorming) 4c Identify Root Cause (Fishbone, Org Chart, Mind-Map, etc)

Possible Causes Verification

Machine

N/A N/A
Material

N/A N/A

N/A N/A
Man
Method

N/A N/A
Other

N/A N/A

2 of 7 pages
 2b: Problem Statement (Photos) Supplier Approvals :(must be approved by Supplier Plant, Quality and Production Manager prior to close by Autoliv)

Duplicate PKG ID-UNIT on box

Problem Statement:
Condition is:

Should be:

3 of 7 pages
 Containment Checksheet
Briefly describe containment activity Date Started 9-Dec-14
Date Ended 10-Dec-14
We don't have material at Arcosa warehouse. Material for the next shipment will be
marking with a green dot certified for 1st defect reported.

Scope
1. Determine Containment Criteria (Bookends)
Affected Dates 9-Dec-14 to 10-Dec-14
Part Numbers 629317000
628616500

Customers Impacted N/A

Total QTY of product "at risk" 236

Quarantine
2. Move all suspect product to applicable Nonconforming Area Reconcilation: Total Built/Total Contained
236

Product at Customer Qty: Initials

Product in Transit Qty: 71 Initials S.S.
Shipping Dock Qty: Initials
Warehouse Qty: 165 Initials S.S.
AS412 (GP12) Qty: Initials
Production (WIP) Qty: Initials
Special Builds Qty: Initials
Testing Qty: Initials
Sub Assembly Qty: Initials

3. Clean Point

Lot Number PKG ID-UNIT: 5129760101

Expected Arrival Date to AOA 15-Dec-14
Package Identification (Markings) Green dot

Photo of AIAG label Markings (example)

4 of 7 pages
 7. Yokoten Worksheet
1. Problem Description 2. Photo or Sketch Supplier Information
Supplier Name: Arcosa
Part Number: 12-9-14
NCM Number: 2014 1527
Completed DARs from recent
Duplicate PKG ID-UNIT on box shipments.

3. Read Across
Product Information System Prevention Detection

considered for preventive

What is the frequency for

What is the current scrap

consistent with the latest

preventive maintenance?

it possible to produce
Was the failure mode for

How is operator training

the standard documents
such as PFMEA, CP, SWI,

specifications according

Final Assessment: Is

Final Assessment: Is
Short Term/Long Term
What methods are used

Non-conformance in

conformance to ship
this NCM considered in

What parameters were

What is the frequency?

automated inspection,
inspection method for

How is the automated

rate after production?

it possible for non-

to ensure the product

Are revisions of these

to work instructions?

defined and verified?

Corrective Actions:

standard documents

maintenance for this

Were all parameters

inspection verified?
What is the current
current process?
meets the drawing

defined within the

To reduce/mitigate risk of

will this defect be

Part Numbers: List all

If there is 100%
requirements? producing and shipping a

undetected?
part numbers that could product with this defect

this defect?
be affected, i.e. all parts

detected?
drawing?

product?
corrective actions must be
with same process, studs, assigned if both Final

etc.?
nuts Assessment areas are marked
yes.

Comments Y N Y N Comments Y N Comments Comments Y N Comments Comments Comments Y N Comments Y N

PKG ID is PKG ID is PKG ID is

Label Software Shipping date generated generated Update the label
All Autoliv's Part generated
generate the PKG X X and boxes X N/A automatically No automatically N/A 0 X No software with the
numbers automatically and
ID automatically quantity and it is not and it is not proper configuration
it is not verified
verified verified

5 of 7 pages
 7. Document Review
Y N
1. Did the CA change the process Flow? X If so, please attach revised document below

Y N
2. Did the CA change the PFEMA? X If so, please attached portion of revised document below

Y N
3. Did the CA change the CP? X If so, please attached portion of revised document below

6 of 7 pages
 8-D Summary Sheet
1 NCM Number 2014 1527
Part Number(s): 629317000E Supplier Name and ID Arcosa Date:
Duplicate PKG ID-UNIT on box
2 Problem Statement:
236 236
3 Short Term Containment: Sorting Activities Total Qty Sorted Total Defects Found

4 Root Causes
Label software was programing incorrectly
a. Specific The root cause for this specific occurrence is…

Label software was programing incorrectly

b. Detection The root cause for non-detection is…

Lack training in procedure of PPAP to Engineering and Quality department.

c. Systemic The root cause for the system failure is…

5 Date
Long Term Countermeasures:
Complete

Update label software properly with the configuration IIIIIILLBB.

Specific CA Where: I:Invoice number, L:Line and B:Box number 11-Dec-14
The Invoice number is unique therefore the PKG ID Unit can't be duplicate.

Update label software properly with the configuration IIIIIILLBB.

Detection CA Where: I:Invoice number, L:Line and B:Box number 11-Dec-14
The Invoice number is unique therefore the PKG ID Unit can't be duplicate.

Systemic CA Training to all departments involved into the PPAP procedure. (P20-0104). 6-Jan-15

6 Date Completed Quantity Verified Defects Found Actions (if necessary)

Specific: 12/12/14
Confirm Countermeasures:
Detection: 12/12/14 22 boxes 0
Systematic: 1/9/2015

7 of 7 pages