THE WOODBRIDGE GROUP - 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.: 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)

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:

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?

Target Date:

Actual Date:

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.

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 1 of 9 Rev. 5 18-Nov-03

Instructions

THE WOODBRIDGE GROUP - 8D Response Report

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.

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:

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.

% Effective:
How effective is your ICA so the customer does not see the problem?

Target Date:

Actual Date:

LINK TO DECISION MAKING WORKSHEET & RISK ANALYSIS HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA? 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)? How can you make the problem come and go - prove it - test results - document it. D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):
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.

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

% Effective:

LINK TO DECISION MAKING WORKSHEET & RISK ANALYSIS HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?: How can you make the problem come and go - prove it - test results - document it. D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):
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.

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

Target Date:

Actual Date:

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.

Target Date:

Actual Date:

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

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? Example Customer Company: 1234 Somewhere St. Address: Mytowne, MI Location: 26003 Part No./Code Front Seat Back Cushion Product Name:
INTERNAL or EXTERNAL

D1 TEAM MEMBER NAMES/TITLES: Champion: Al Bossman Team Leader: Joe Smith Team Members: Les Shippet, Stan Tistics, Ima Goodguy

5/25/2003 BR-03-001 Date Open: 8D No.: 5/26/2003 Initial Response: 6/10/2003 Target Close Date: 5/30/03, 6/5/03 Revision Date(s): Joe Smith 8D Initiator: Al Bossman Supervisor: 6/9/2003 Actual Close Date: 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
% Effective: Target Date: Actual Date:

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):

100%

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. HOW DID YOU VERIFY THE ROOT CAUSE(S)? 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): 1. Change robot pour pattern 2. Change auto vent. HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?: Monitored 30 pours for splash and checked auto vent after 30th pour for no clogs. 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. 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). D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE: Mistake Proofing: How are you going to ensure it can't happen again? 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 Flowchart Proc./Work Instr. Control Plan Check boxes that apply: D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.
30-May-03 29-May-03 Target Date: Actual Date:

1. 70% 2. 30%

% Effective:

100%

Target Date:

Actual Date:

05-Jun-03 05-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)

0

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

(Type in D2 here)

2. Description of Problem WHAT

Object

IS

IS NOT

GET INFO ON

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)

(Type in D2 here) (Type in D2 here)

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

2. Description of Problem WHAT

Object

IS

IS NOT

3. Deductions About Facts and Other Information 3a. Differences 3b. Changes

Date
A

4. Possible Causes List Change-How Theories

Defect 0 0

WHERE
Seen on object 0 0

Seen geographically 0 0

WHEN
First seen 0 0

When else seen 0 When seen in process (life cycle) 0

G 0 0

HOW BIG
How many objects have the defect? How many defects per object? 0 0 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? 0 Updated By:

WGCPF-001 page 5 of 9 Rev. 5

0 Update Date:
18-Nov-03

Update #:

TESTING POSSIBLE CAUSES (D4 Continued)

Ch an g Th e-Ho eo w rie s

"IS's" 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 Rev. 5

Update Date:
18-Nov-03

Update #:

DECISION MAKING WORKSHEET (D3 & D5)

(4) CHOICES AVAILABLE - (INNOVATE)

(1) END RESULT: (2) CRITERIA:

GIVENS: (mandatory, measurable, realistic)

A
(5) INFO

B
Y/N (5) INFO

C
Y/N (5) INFO

D
Y/N (5) INFO Y/N

(3) How
Important

(5) How INFO

Good

(5) How INFO

Score
Good

(5) How INFO

Score
Good

(5) How INFO

Score
Good

WANTS: flexible limits, subjective, realistic

(1-10)

(0-10)

(0-10)

(0-10)

(0-10)

Score

0 0 0 0 0 0 0 0 0 0 Relative MERIT (total score)

WGCPF-001 page 7 of 9

0 0 0 0 0 0 0 0 0 0 0 Update Date: 0
18-Nov-03

0 0 0 0 0 0 0 0 0 0 0 Update Rev #:

0 0 0 0 0 0 0 0 0 0 0

0 0 Updated By:
Rev. 5

DECISION MAKING WORKSHEET - RISK ANALYSIS (D3 & D5)

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

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

Investigate one choice at a time

1st Choice

2nd Choice

3rd Choice

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?

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 #:

PLANNING AND PROBLEM PREVENTION WORKSHEET (D6)

3. POTENTIAL PROBLEMS 4. PRIORITY P S 5. POSSIBLE CAUSES 6. PREVENTION ACTIONS 7. PROTECTION ACTIONS 8. CUES (DATE OR EVENT) 9. WHO

1. OBJECTIVE OF THE PLAN (Goal with timing): 2. KEY STEPS

Revised By:
WGCPF-001 page 9 of 9 Rev. 5

Revision Date:

Revision #:
18-Nov-03