DATE / PERIOD: REVIEW BY: REVIEW SAMPLE:

CODE / CAVITY: NAME: PROJECT:

N° Defect Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14

NOTE:
 DATE / PERIOD: REVIEW BY: REVIEW SAMPLE:
CODE / CAVITY: NAME: PROJECT:

N° Defect Quantity
1
2
3
4
5
6
7
8
9
10

NOTE:
 Kaizen Idea Card
Name: Date:

Idea:

Date: Addressed Within 7 Days with

Approved By: Submitters Initials:

See Reverse Side for:
Implementation Details
7 Types of Waste
Woodbridge Product
5 Questions of Continual Improvement

Who:

Estimated Completion Date:

Date Entered in KMS:

d Kaizen Id
Dept: Name:

Idea:

essed Within 7 Days with Submitter Date:

bmitters Initials: Approved By:

See Reverse Side for:
Implementation Details
7 Types of Waste
oodbridge Production System
5 Questions of Continual Improvement

pletion Date:
Kaizen Idea Card
Date: Dept:

Addressed Within 7 Days with Submitter

Submitters Initials:

Woodbridge Production System

Who:

Estimated Completion Date:

Date Entered in KMS:

 Kaizen Idea Card
Name: Date:

Idea:

Date: Addressed Within 7 Days with Su

Approved By: Submitters Initials:

See Reverse Side for:
Implementation Details
7 Types of Waste
Woodbridge Productio
5 Questions of Continual Improvement

Who:

Estimated Completion Date:

Date Entered in KMS:

d Kaizen Id
Dept: Name:

Idea:

ssed Within 7 Days with Submitter Date:

mitters Initials: Approved By:

See Reverse Side for:
Implementation Details
7 Types of Waste
oodbridge Production System
5 Questions of Continual Improvement

etion Date:
Kaizen Idea Card
Date: Dept:

Addressed Within 7 Days with Submitter

Submitters Initials:

Woodbridge Production System

Who:

Estimated Completion Date:

Date Entered in KMS:

 Kaizen Idea Card
Name: Date:

Idea:

Date: Addressed Within 7 Days with Su

Approved By: Submitters Initials:

See Reverse Side for:
Implementation Details
7 Types of Waste
Woodbridge Productio
5 Questions of Continual Improvement

Who:

Estimated Completion Date:

Date Entered in KMS:

d Kaizen Id
Dept: Name:

Idea:

ssed Within 7 Days with Submitter Date:

mitters Initials: Approved By:

See Reverse Side for:
Implementation Details
7 Types of Waste
oodbridge Production System
5 Questions of Continual Improvement

etion Date:
Kaizen Idea Card
Date: Dept:

Addressed Within 7 Days with Submitter

Submitters Initials:

Woodbridge Production System

Who:

Estimated Completion Date:

Date Entered in KMS:

 Kaizen Idea Card
Name: Date:

Idea:

Date: Addressed Within 7 Days with Su

Approved By: Submitters Initials:

See Reverse Side for:
Implementation Details
7 Types of Waste
Woodbridge Productio
5 Questions of Continual Improvement

Who:

Estimated Completion Date:

Date Entered in KMS:

d Kaizen Id
Dept: Name:

Idea:

ssed Within 7 Days with Submitter Date:

mitters Initials: Approved By:

See Reverse Side for:
Implementation Details
7 Types of Waste
oodbridge Production System
5 Questions of Continual Improvement

etion Date:
Kaizen Idea Card
Date: Dept:

Addressed Within 7 Days with Submitter

Submitters Initials:

Woodbridge Production System

Who:

Estimated Completion Date:

Date Entered in KMS:

 Kaizen Idea Card
Name: Date:

Idea:

Date: Addressed Within 7 Days with Su

Approved By: Submitters Initials:

See Reverse Side for:
Implementation Details
7 Types of Waste
Woodbridge Productio
5 Questions of Continual Improvement

Who:

Estimated Completion Date:

Date Entered in KMS:

d Kaizen Id
Dept: Name:

Idea:

ssed Within 7 Days with Submitter Date:

mitters Initials: Approved By:

See Reverse Side for:
Implementation Details
7 Types of Waste
oodbridge Production System
5 Questions of Continual Improvement

etion Date:
Kaizen Idea Card
Date: Dept:

Addressed Within 7 Days with Submitter

Submitters Initials:

Woodbridge Production System

Who:

Estimated Completion Date:

Date Entered in KMS:

 ISHIKAWA DIAGRAM 12/30/1899 0:00
Business Unit: Date:
Defect Description:

MAN MACHINE METHOD SALARY Team TITLE

20 20 20
19 19 18
18 18 18
17 17 17
16 16
16
15 15 15
14 14 14
13 13
13
12 12 12
11 11 11
10 10 10
9 9 9
8 8
8
7 7
7
6 6
6
5
4
5

4
5
4
Problem Definition
3 3 3
2 2 2
1
1 1

1
1 1 0
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9 Natural Work Team TITLE
10 10 10
11 11 11
12 12 12
13 13
13
14 14 14
15 15 15
16 16 16
17 17 17
18 18
18
19 19 19
20 20 20

MOTHER NATURE MEASUREMENT MATERIAL

 CAR Report #:

Is / Is Not Matrix
Commonly used to define what is in the scope and is not in the scope or to be considered at this time. Typically used for a seemingly simple or common problem with no obvious cause or effective solution known by the process experts.
Can be used when defining a solution to determine what to include and what to exclude. Compare what we know it is with what we know it is not and form hypothesis for further analysis. I.e.. Failure mode recreation What, where, when, why and how much.
If at the end of the exercise an idea does not stand out to the group as the best option, use the List Reduction, Multi-voting, Affinity Diagram or Effective-Achievable Chart tools.

Problem Description:

Further Actions or Investigations Needed Outcome

Does Not Explain Does Explain
Problem Is Problem Is Not Possible Causes Action Champion Due Date
Is / Is Not Is / Is Not
WHAT

What occurs?

What affected?
WHERE

Where in the Process can you

find the Defect

Where detected in process?

Where located on object?

WHEN

When occurs?

When first detected?

When - Repeat occurrence?

HOW

How long did it occur?

Patterns or trends in occurrence?

Occur before, during or after

other events?

Is there a defined frequency?

How serious is problem?

WHO HOW MANY

How many occurrences

detected?
How many objects or situations
have problem?
How many problems per
unit/object?

Who is involved in problem

detection?
Who is involved in problem
occurrence?
OTHER
 CAR Report #:

Fault Tree
Use a Fault Tree to analyze and record all the possible failure modes, causes, contributions and solutions.
Best used for event analysis or troubleshooting. Commonly used for complex event, activities, or process issues.
Typically must be used with another analysis technique to identify specific cause of events.
If at the end of the exercise an idea does not stand out to the group as the best option, use the
List Reduction, Multi-voting, Affinity Diagram or Effective-Achievable Chart tools.

Undesirable Event

What?

Failure Mode 1

How?

Cause 1.1 Cause 1.2

Why?

Contributors 1.1.1 Contributors 1.1.2 Contributors 1.1.3 Contributors 1.1.4 Contributors 1.2.1 Contributors 1.2.2 Contributors 1.2.3 Contributors 1.2.4

Because?

Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions Solutions
1.1.1.1 1.1.1.2 1.1.2.1 1.1.2.2 1.1.3.1 1.1.3.2 1.1.4.1 1.1.4.2 1.2.1.1 1.2.2.1 1.2.2.1 1.2.2.2 1.2.3.1 1.2.3.2 1.2.4.1 1.2.4.2

#REF!
 Corrective Action Report - 8 Step Process
Customer/Company: Woodbridge CAR #:
Cust/Ext Assigned#: Cust # or RMA, if app.:
Cust/Comp Location: CAR Initiator:
Cust/Comp Part #: Date Open:
Vehicle / Program: Initial Response Date:
INTERNAL EXTERN Actual Close Date:
1 TEAMor
MEMBER NAMES/TITLES: AL
Champion:
Process Owner:
Team Members:
2 PROBLEM STATEMENT/DESCRIPTION (one defect per CAR)

3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S): Date

(Consider: customer site/warehouse, in transit, WFC warehouse/on line/lab/hold, etc. % Effective Implemented Verified By
Note how product and/or packaging will show containment activity has been completed.)

4 DEFINE AND VERIFY ROOT CAUSE(S): % Contribution

(Must use a formal problem solving technique supported with real data: See Effective Problem Solving Process Toolbox.)

5 CHOOSE AND IMPLEMENT PERMANENT CORRECTIVE ACTION(S) (PCA):

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

HAS ERROR PROOFING BEEN IMPLEMENTED THROUGH THESE CAs (100% effective)? Yes: No:

IF NO, EXPLANATION OF
ERROR PROOFING CONSIDERATION:

6 VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA) and VERIFY PREVENTIVE ACTIONS:

Systemic actions: How are you going to confirm effective actions are still in place long term and the Target Date Actual Date
problem cannot reoccur?

7 SYSTEM PREVENTIVE ACTIONS TO PREVENT RECURRENCE: Target Date Actual Date

HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWEDPr

AGAINST DOCUMENTS / PROCESSES?:
Coc
ales Map/Proc./
Check boxes FM Toolin Preventive/Predictive
that apply: Control Plan ibs Work Set-Up Othe
EA
Add to Internal Audit g/ Instr./Form Maintenance
Process/Instruction
raFl r:
EXPOSURE / IMPACT ANALYSIS, ARE SIMILAR PRODUCTS / PROCESSES Gaging s
TO THIS FAILURE MODE OR IMPACTED BY THIS ROOT CAUSE?
tiowEXPOSED Yes: No:
o
IF YES, AFFECTED TEAM NOTIFIED: n
8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team. Execute CAR Closure activities

All initial CAR's and revisions must be sent to appropriate personnel for review prior to sending to the internal/external customer within required timing.
Completed CARs require internal closure via the "CAR Closure Form".
 Corrective Action Report - Summary CAR Report #:

CAR Classification: A B C

Corrective Action Report Type - Class A or B Other Action Report Type - Class C
1 Customer Concern / Complaint 4 Internal - Continual Improvement
Nonconforming Customer Name: Qualit Maintenance /
Product Process /
Deliveryor
orService
Logistics Location:
y Plant Materials
Engineering
/
Manufacturin
Concern
Othe Tooling / Design / Delivery
g
r: Product Engineering
Containment CSI CS Date Reported: Health & Ergonomi Environ
Repeat
Required: II Safety mental
Reported By: Chemical Release Report No.: cs
Nonconforman
ce Medical Aids Report No.:

2 Supplier Concern / Complaint Lost Time Report No.:

Nonconforming Supplier Name: Preventive Action

Product or
Delivery orService
Logistics Location: Oth
Concern
Othe er:
PCN Number:
r:
Containment C CS
Repeat
Required: SI II
Nonconforman
ce
3 Audit Concern / Non conformance Ex
Opportunity for ter
TS-16949 Minor Internal
Improvement nal
Associated Clause or Element Number:
ISO-14001 Nonconforman
Major
HS&E ce
Nonconformanc
Repeat
Auditor(s):

Materials e
Nonconformanc Auditee(s):

Human Othe
e
Resources r:
Plant / Location: Division:

Part Number(s): Vehicle Program:

Description of Problem or Concern Reported:

External Contacts:
1. Name: Title: Company:

Tel.: Email: Fax.:

2. Name: Title: Company:

Tel.: Email: Fax.:

 CAR Report #:

Corrective Action Report - Verification & Closure

Required to be completed for each CAR unless otherwise authorized by the Corporate Quality Director.
To be conducted and completed by a qualified quality auditor or quality associate and noted in section 4.
Not to be completed by the CAR Champion (not the same person who completed the CAR).

1. All sections of CAR are completed and accurate?

If "no" or "N/A" explain:
Yes No
N
Issue Exposure Evaluated? Yes N/A
o
Issue Communication Complete? Yes N/
N A
Error Proofing Implemented? Yes N/A
o
2. Permanent Corrective Actions Verified for completion, training, and implementation:
Verify each permanent corrective action noted on the CAR was completed using GEMBA (go and see). Document below.
1
2
3

3. Preventive Actions Verified (document / system updates) for completion, approval/release, training and implementation:
PFME Control Stand Proce
Process Flow WI Form N/A
A Plan ard dure
Calibr Too Gagin
PM Set-Ups Audit/Kamishibai
ation ling g
Other:

4. Are verified Corrective and Preventive Actions complete, implemented, & effective?
Verified By Yes No
(name):
Title:
Date:

4.1 If "no" above, CAR cannot be closed. Proceed with 4.1.1 - 4.1.3 below.
4. 1.1 Note actions required and return to assigned champion to complete:
Actions required:
Champion Assigned:
4.1.2 Re-verification (repeat as required)
Are verified Corrective and Preventive Actions complete, implemented, and effective?
Yes No
If "no", CAR cannot be closed. Go to 4.1 and repeat. Notify management.
4.1.3 Re-Verification completed with all Corrective & Preventive Actions complete, implemented & effective.
Name:
Title:
Date:

Comments:

5. CAR Closure - Complete The Applicable Sections Below

5.1 Internal Audit CAR Closure Approval:
MR / Auditor Approval typically required. Approved: Yes No
Auditor Comments: Auditor Name:
Date:

5.2 External Customer, Audit, & Other CAR Submission

Customer/Auditor/Other Name receiving completed CAR:
Date completed CAR sent to Customer: 0
CAR delivered to customer via: 0
5.3 ALL (Internal & External) CAR Closure (required):
CAR Closed? Yes No
CAR Log Updated? Yes No
CAR Record & Evidence filed? Yes No
6. Congratulate the TEAM Recognize the collective efforts of the team.
Problem Statement:

Task ID Action

TASK ID Action
 COPQ Tracker Revision Log
Rev.
Level Description of Revision/ Change Date Released By
1.0 Format Document 12/04/15 Don Fisher
2.0 Visual Basic Coding 12/05/15 Jeff Fisher
2.1 Addition of Supporting 12 supporting documents 12/06/15 Don Fisher
2.2 Addition of Corrective Action forms (Visual Basic Coding) 12/07/15 Don Fisher
2.3 Modified e-mail distribution code (Visual Basic Coding) 12/08/15 Don Fisher
2.4 Addition of Action Plan & History Log (Visual Basic Coding) 12/09/15 Don Fisher
2.5 Initial Release to Regional Quality Managers for Review 12/09/15 Don Fisher
2.6 Connection to COPQ Lessons Learned Database 12/11/15 Don Fisher
2.7 Addition of Control Number associated with WOL/ Standard 01/11/16 Don Fisher
2.8 Addition of BOB & WOW 01/14/16 Don Fisher
2.9 VB Update for data and file transfer to Troy drive 01/17/16 Jeff Fisher
3.0 Updated e-mail address distribution & incorporate PDCA option 01/28/16 Don Fisher
3.1 Addition of Save to PDF Options for sending individual documents to Customers 02/09/16 Don Fisher
3.2 VB Code for COPQ Tracker updates & Lessons Learned Database Back-up 02/15/16 Jeff Fisher
3.3 Added Materials to the drop down menu 04/12/16 Don Fisher
3.4 Updated e-mail address distribution to include Proseat facilities 04/19/16 Don Fisher
3.5 Simplified code to enable upload to lessons learned database 04/19/16 Jeff Fisher
3.6 Updated e-mail address distribution to Corporate (North American) Technical Services Group 04/19/16 Don Fisher
3.7 Addition of Roadmap/ QI Macro Control Chart applcation, wrapped txt. for Is/Is Not's page 05/04/16 Don Fisher
3.8 Updated Action Plan to include Radar tracking system, updates distribution 06/15/16 Don Fisher
3.9 Simplified Team Member e-mail string, updated distribution, removed links 06/22/16 Don Fisher
4.0 Added clarity for tracking Budgeted vs Non-Budgeted Savings 11/03/16 Don Fisher
4.1 Addition of Standardization Imparative (3 Questions) 11/15/16 Don Fisher
4.2 Addition of 5W & 2H 11/17/16 Don Fisher
4.3 Addition of GR&R and Control Chart 11/28/16 Don Fisher
4.4 Addition of Problem Solving Formats ie.. 8D, 5P, CAR, QPR, A3, TTR, QN 12/02/16 Don Fisher
4.5 Addition of Savings Calculator 12/06/16 Don Fisher
4.6 Addition of occurrence dropdown menu, reformat home page 12/12/16 Don Fisher
4.7 Populate Ishikawa/ Fishbone Failure Modes 12/15/16 Don Fisher
4.8 Addition of CP, PF, DFMEA Confirmation Check box's, replaced radial buttons on home page 12/17/15 Don Fisher
4.9 vb code for required updates beyond 4.9 release 12/18/16 Don Fisher
5.0 vb code updates to connect/ transfer additional data points to database 12/19/16 Don Fisher
5.1 Updated vb code for Data Transfer 12/21/16 Don Fisher
5.2 Updated calculations in GR&R for Auto Calc. 01/25/16 Don Fisher
5.3 Updated vb code to clear savings calculator 02/13/16 Don Fisher
5.4 vb code updated Save Fishbone to desktop as .pdf file 02/13/16 Don Fisher
5.5 vb code to clear fishbone diagram; updated distribution list 02/13/16 Don Fisher
5.6 Update Plant Distribution (email) Log 03/03/18 Don Fisher
5.7 Microsoft vb code fix - Transfer of lessons learned to database (Office 2017 Update Patch) 03/11/18 Jeff Fisher
 Gridlines BOB WOW
A B C D E F G A B C D E F G
1.) NOTES:
1 1

2 2

3 3

4 4

5 5

6 6

7 7

BOB WOW
A B C D E F G A B C D E F G
2.) NOTES:
1 1

2 2

3 3

4 4

5 5

6 6

7 7
 BOB WOW
A B C D E F G A B C D E F G
3.) NOTES:
1 1

2 2

3 3

4 4

5 5

6 6

7 7

BOB WOW
A B C D E F G A B C D E F G
4.) NOTES:
1 1

2 2

3 3

4 4

5 5

6 6

7 7
 7 7

BOB WOW
A B C D E F G A B C D E F G
5.) NOTES:
1 1

2 2

3 3

4 4

5 5

6 6

7 7
 Place Title Here

TAR RESULTS:
GET
:

Plan Do

Chec Act
k
 Control Chart Data

USL (Need to input value) LSL (Need to input value)

Sub Sub Sub Sub Sub Sub Sub Sub

Group Data Group Data Group Data Group Data Group Data Group Data Group Data Group Data
1 26 51 76 101 126 151 176
2 27 52 77 102 127 152 177
3 28 53 78 103 128 153 178
4 29 54 79 104 129 154 179
5 30 55 80 105 130 155 180
6 31 56 81 106 131 156 181
7 32 57 82 107 132 157 182
8 33 58 83 108 133 158 183
9 34 59 84 109 134 159 184
10 35 60 85 110 135 160 185
11 36 61 86 111 136 161 186
12 37 62 87 112 137 162 187
13 38 63 88 113 138 163 188
14 39 64 89 114 139 164 189
15 40 65 90 115 140 165 190
16 41 66 91 116 141 166 191
17 42 67 92 117 142 167 192
18 43 68 93 118 143 168 193
19 44 69 94 119 144 169 194
20 45 70 95 120 145 170 195
21 46 71 96 121 146 171 196
22 47 72 97 122 147 172 197
23 48 73 98 123 148 173 198
24 49 74 99 124 149 174 199
25 50 75 100 125 150 175 200

# sub groups Spec Limits Spec Limit A single point outside the control limits
On Control Limits Three Sigma Limit Two of three pts outside the two sigma limit
Two Thre
Zone B Two Sigma Limit Four of Five pts outside the one sigma limit
e
Fou Fiv e
Si Zone A One Sigma Limit Eight in a row on the same side of centerline
r (Need to choose
e sub group)
x Average ● If a point fails more than one test, only one color will
be displayed.
Zone Analysis can be deleted directly from the chart.

Control Chart

Individuals Chart

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0
AVG
UCL
USL
LCL
LSL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Moving Range Chart

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

#DIV/0! Xbar/IMR Chart Avg ### Xbar one sigma Upper Limit ### Rbar one sigma Upper Limit
#DIV/0! Range Chart Avg ### Xbar two sigma Upper Limit ### Rbar two sigma Upper Limit
#DIV/0! Rbar/d2 ### Xbar three sigma Upper Limit ### Rbar three sigma Upper Limit
0 Number of samples ### Xbar one sigma Lower Limit ### Rbar one sigma Lower Limit
1 Subgroup size ### Xbar two sigma Lower Limit ### Rbar two sigma Lower Limit
0 Number of subgroups ### Xbar three sigma Lower Limit n/a Rbar three sigma Lower Limit
0.0 Minimum value 0.0 Maximum value ### Standard Deviation
#DIV/0! Cpk1 Upper ### Cpk2 Lower ### CpK

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