PROTEC - 8D Response Report

WHO IS EFFECTED BY THE PROBLEM?

Company:
Address:
Location:
Part No./Code
Product Name:
INTERNAL

or

EXTERNAL

D1 TEAM MEMBER NAMES/TITLES:

Champion:
Team Leader:
Team Members:

Date Open:
8D No.: 2014/8D/001
Customer
Initial Response:
Complaint No.:
Target Close Date:
Revision Date(s):
8D Initiator:
CUSTOMER
8D Initiator's Spvr:
Actual Close Date:
D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)

D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):

%
Effective:

Target
Date:

Actual
Date:

HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?

D4 DEFINE AND VERIFY ROOT CAUSE(S):

% Contribution:

HOW DID YOU VERIFY THE ROOT CAUSE(S)?

D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):

% Effective:

HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:

D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):

Target
Date:

Actual
Date:

Target
Date:

Actual
Date:

HOW WILL YOU VALIDATE THE PCA?

D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE:

Mistake Proofing: How are you going to ensure it can't happen again?

HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:

Proc./Work Instr.
FMEA
Flowchart
Control Plan
Check boxes that apply:
D8 TEAM AND INDIVIDUAL RECOGNITION:

Add to Internal Audit

THE WOODBRIDGE GROUP - 8D Response Report

Instructions

WHO IS EFFECTED BY THE PROBLEM?

Company:
Address:
Location:
Part No./Code
Product Name:
INTERNAL

or

EXTERNAL

D1 TEAM MEMBER NAMES/TITLES:

Champion:
Team Leader:
Team Members:

Date Open:

8D No.:

Customer
Initial Response:
Complaint No.:
Target Close Date:
Revision Date(s):
8D Initiator:
8D Initiator's Spvr:
Actual Close Date:
D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)

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.

LINK TO PROBLEM SOLVING WORKSHEET - PROBLEM DESCRIPTION

D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):

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.

LINK TO DECISION MAKING WORKSHEET & RISK ANALYSIS

HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?

%
Effective:

Target
Date:

Actual
Date:

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.
D4 DEFINE AND VERIFY ROOT CAUSE(S):

% Contribution:

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.

LINK TO PROBLEM SOLVING WORKSHEET - ROOT CAUSE WITH THEORY TESTING

HOW DID YOU VERIFY THE ROOT CAUSE(S)?

What % of the
problem is caused by
the root cause(s)
(must have 100%
total)

How can you make the problem come and go - prove it - test results - document it.
D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):

% Effective:

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.

LINK TO DECISION MAKING WORKSHEET & RISK ANALYSIS

HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:

How effective is your

PCA so the problem
is cured not masked?
(must have 100%
total)

How can you make the problem come and go - prove it - test results - document it.
D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):

Target
Date:

Actual
Date:

Target
Date:

Actual
Date:

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 PLANING AND PROBLEM PREVENTION WORKSHEET

HOW WILL YOU VALIDATE THE PCA?
Use validation tools for long term results: Trend - Pareto - Paynter, etc.
D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE:
Mistake Proofing: How are you going to ensure it can't happen again?
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.

Note: Develop Action Plan (can use worksheets to help brainstorm)

HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:
FMEA
Proc./Work Instr.
Flowchart
Check boxes that apply:
Control Plan
D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.

Add to Internal Audit

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
WGCPF-001 page 2 of 9

Rev. 5

18-Nov-03

THE WOODBRIDGE GROUP - 8D Response Report

WHO IS EFFECTED BY THE PROBLEM?
Company:
Example Customer
Address:
1234 Somewhere St.
Location:
Mytowne, MI
Part No./Code
26003
Product Name:
Front Seat Back Cushion
INTERNAL

or

EXTERNAL

D1 TEAM MEMBER NAMES/TITLES:

Champion:
Al Bossman
Team Leader:
Joe Smith
Team Members:
Les Shippet, Stan Tistics, Ima
Goodguy

Date Open:
5/25/2003
8D No.:
BR-03-001
Initial Response:
5/26/2003
Target Close Date:
6/10/2003
Revision Date(s):
5/30/03, 6/5/03
8D Initiator:
Joe Smith
Supervisor:
Al Bossman
Actual Close Date:
6/9/2003
D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)
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

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.
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):

%
Effective:

100%

Target
Date:

Actual
Date:

26-May-03 26-May-03

% Contribution:

1. Foam splashing on seal. 2. Malfunctioning auto vent: Cleaned after demold, proper air pressure and cycling
is occurring but still malfunctioning by clogging.
1. 70%

HOW DID YOU VERIFY THE ROOT CAUSE(S)?

2. 30%

Can make voids come and go by altering pour pattern without splash and with splash. New auto vents produce
no clogs thus no voids.
D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):

% Effective:

1. Change robot pour pattern 2. Change auto vent.

HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:

100%

Monitored 30 pours for splash and checked auto vent after 30th pour for no clogs.
Target
Date:

D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):

Actual
Date:

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.
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 (npchart 10 pieces every hour at end of line).
D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE:
Mistake Proofing: How are you going to ensure it can't happen again?

Target
Date:

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?:
FMEA
Proc./Work Instr.
Flowchart
Control Plan
Check boxes that apply:
D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.

30-May-03 29-May-03

5-Jun-03

Actual
Date:
5-Jun-03

Add to Internal Audit

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
WGCPF-001 page 3 of 9
Rev. 5
18-Nov-03

PROBLEM DESCRIPTION (D2)

2014/8D/001

1. Operational
Definition
What's
wrong with what?
Why?

2. Description
of Problem
WHAT

(Type in D2 here)

IS

IS NOT

GET INFO ON

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:
WGCPF-001 page 4 of 9

Update Date:
Rev. 5

Update #:
18-Nov-03

PROBLEM SOLVING WORKSHEET (D4)

2014/8D/001

1. Operational Definition

(Type in D2 here)

What's wrong with what? Why?

2. Description
of Problem
WHAT

IS

IS NOT

(Type in D2 here)

3. Deductions About Facts and Other Information

3a. Differences
3b. Changes

4. Possible Causes
List Change-How Theories

Date
A

Object
0

Defect

B
0

WHERE
Seen on object
0

Seen
geographically

D
0

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?

5. Test causes for probability (+, -, ?) Page 2

Does it explain Is/Is Not fact?
6. Steps to verify Root Cause?
(make the problem come and go)

What is the trend?

Updated By:
WGCPF-001 page 5 of 9

Update Date:
Rev. 5

Update #:
18-Nov-03

Ch
Th ang
eo e-H
rie
s ow

"IS's"

TESTING POSSIBLE CAUSES (D4 Continued)

2014/8D/001

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Comments/
Follow-Up
Items

Updated By:
WGCPF-001 page 6 of 9

Update Date:
Rev. 5

18-Nov-03

Update #:

DECISION MAKING WORKSHEET (D3 & D5)

2014/8D/001

(1) END RESULT:

(4) CHOICES AVAILABLE - (INNOVATE)

(2) CRITERIA:

GIVENS: (mandatory, measurable, realistic)

(5) INFO

(3)

WANTS: flexible limits, subjective, realistic

Relative MERIT (total score)

WGCPF-001 page 7 of 9

How
Important

INFO

(1-10)

Y/N (5) INFO

Y/N (5) INFO

Y/N (5) INFO

(5) How
Good

(0-10)

0
0
Updated By:

Score

(5) How

INFO

Good

(0-10)

INFO

(5) How
Good

(0-10)

Score

INFO

(5) How
Good

(0-10)

Score

0
Update Date:

Rev. 5

Score

Y/N

18-Nov-03

0
Update Rev #:

DECISION MAKING WORKSHEET - RISK ANALYSIS (D3 & D5)

2014/8D/001

(6) RISK ANALYSIS: State your risks in "IFTHEN" terms.

1st Choice

Investigate one choice at a time

1. RISK

What characteristics of
this choice may fail to
satisfy the GIVENS?

2. RISK

What features or
characteristics of this
choice compromise or
threaten an important
WANT?

"If we do this, what might happen, contrary to our interest?"

2nd Choice

3rd Choice

3. UNIVERSAL
Use the checklist to stimulate ideas.
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).
Updated By:
WGCPF-001 page 8 of 9

Rev. 5

P = Probability (1-10)

S = Severity (1-10)
Update Date:
18-Nov-03

7. Make the Final Balanced Choice

Update Rev #:

2014/8D/001

PLANNING AND PROBLEM PREVENTION WORKSHEET (D6)

1. OBJECTIVE OF THE PLAN (Goal with timing):

2. KEY STEPS

3. POTENTIAL PROBLEMS

4. PRIORITY
P
S

Revised By:
WGCPF-001 page 9 of 9

Revision Date:
Rev. 5

5. POSSIBLE CAUSES

6. PREVENTION ACTIONS

Revision #:
18-Nov-03

7. PROTECTION ACTIONS

8. CUES (DATE OR EVENT)

9. WHO