Instructions

Based on the Honda 2005 5-P training, the questions to be answered for each block have been listed. It is recommended that you replace the question(s) with your answer. In Box 1A, a picture of the defect can also be referenced. Since there is not much space in Box 1A, the picture can be placed as an attachment. In Box 1B, any of the items listed can be used-- these are meant to be suggestions of the type of information expected. Items can be placed as attachments.

In Box 2C, the root cause analysis can be completed in less than 5 why's. If there are multiple potential ro causes that you would like to countermeasure, the 5 why analysis for each can be added as an attachmen Root causes for BOTH occurrence and for non-detection must be listed. In Box 2D, the explaination of WHY the root cause was selected is to be listed. (The root cause fits all of listed in 1A)

Dates for countermeasures and verifications should be listed. Data supporting effectiveness should be pr Honda indicated that side 2 (5-P Backside) was to be use by teams to determine root cause but that this brainstorming side did not have to be sent to customers. Attachments are optional. Any information to help clarify the defect, root cause, show countermeasures, or data to verify effectiveness is appropriate.

s
block have been listed.

uch space in Box 1A,

ions of the type of

ere are multiple potential root n be added as an attachment.

(The root cause fits all of the data

effectiveness should be provided.

ne root cause

PROBLEM STATEMENT <What part model and type has the problem and what is the defect?
Only 1 part and 1 defect per sheet>

5 PRINCIPLES FOR PROBLEM SOLVING WORK SHEET

1-B

PREPARING SECTION
SECTION OR SUPPLIER: TBDN Approved By Approved By Checked By Prepared By Report to be Made to Approved By SECTION

Checked By

1-A

PROBLEM DEFINITION (PROBLEM SIDE)

PROBLEM DEFINITION (CLARIFYING FACTS) (attach add'l sheets if necessary)

N units were sorted, and n units were found defective. Lot numbers/ sort quantities A. WHO: <Who found the problem> B. WHAT: <Reiterate Problem Statement> Part Analysis: <Any of the following - Visual observations, Dimentional comparison, test results, technical C. WHERE: <Location of occurrence and where on the part is the trouble reports, changes occurring around 1st problem date, new manpower?, new material?, die adjusted?, new located> equipment?> D. WHEN: <Date and time problem was first found, has it reoccurred, is it Process Analysis: <Any of the following: Process Flow, flow chart; Statistical History: trends, histogram, continuous, sporadic or periodic, and manufacturing date of first observation> CpK, SPC charts, %NG, Reject History, etc> E. WHY: <Content of complaint> F. HOW: <How was problem found - visual inspection, customer complaint, etc> G. QUANTITY: <How many parts or units have this problem, how many defects on each object, and is problem getting better, worse or staying the same> Why, Why (Both Occurence & Nondetection) (circle causes to be countermeasured) IDENTIFY ROOT CAUSE (causes from 2C to be C/M

2-C

2-D

and why selected)

WHY(1)

WHY(2)

WHY(3)

WHY(4)

WHY(5)

The root cause for occurrence is The root cause for non-detection is We determined that this is the root cause by... The data show...

What is the immediate <--- What is the cause <--- What is the cause <--- What is the cause <--- What is the cause cause of the problem? of the previous cause? of the previous cause? of the previous cause? of the previous cause?

Why was the problem not detected and contained at the source?

<--- What is the cause <--- What is the cause <--- What is the cause <--- What is the cause of the previous cause? of the previous cause? of the previous cause? of the previous cause?

Identify Temporary & Permanent, Responsibility and Date

CORRECTIVE COUNTERMEASURE(S)

CONFIRM COUNTERMEASURE(S)

We took these actions to confirm the countermeasure is in place and working: <Statistical Proof, Supplier Self Audit, C/M Verification, Durability Testing, etc.>

Vert, Horiz & back to employee The system has been changed <how?> to prevent similar occurrences in the future on this and other products. The countermeasures have been applied across <products, production lines, plants, companies> to prevent the same thing from happening elsewhere.

FEEDBACK/FEEDFORWARD

2-A

Identify Root Cause

(Brainstorming)

2-B

Identify Root Cause (Fishbone, Org Chart, Mind-Map, etc Why, Why Why Analysis)

Possible Causes

Verification

Method

Man

Material

Machine

Other

Attachment A

Attachment B

Attachment C

Attachment D

Attachment E

Attachment E