G8D REPORT

Title:

Date Opened:

Last Updated:

Status (Open/Closed):

Type (Issue source):

Date Closed:

Product/Process Information (Part number & Description/ Process Description):

Organization (Supplier Name/GSDB):

D Symptom(s) (Symptom description & Quantity):

D Emergency Response Action(s) (Action, method and criteria & Validation . Quantity of parts involved)

Date Implemented:

Data Removed:

D1 Team:

D2 - Problem
Name

Dept/Supplier

Phone

D2 Problem Statement (What):

Champion
Team Leader

D2 Problem Description (When, where & how big)

Team members

Who detect:
Where:
When:
How:
How many bad parts:
D3 Interim Containment Action(s) (Action, method and criteria)

% Effective:

Date Implemented:

Data Removed:

D4 Root Cause(s) and Escape Point(s) (Why's):

Verification: (How/Method, who):

% Contribution:

Root cause (occurrence):

(Why did we have the problem?)

Escape Point (no detection):

(Why did the problem reach the Customer?)

System Failure (prevention):

Why did our system allow it to occur?

D5 Identified Permanent Corrective Action(s):

% Contribution:

D6 Implemented Permanent Corrective Action(s):

Implementation Date

Validation (How/Metric data, Who):

D7 Prevent Actions:
Date

Responsible

Date

DFMEA Review
PFMEA Review
Control Plan Review

Pokayokes Review/Added
New PSW (if applicable)
Maintenance Plan

Operation Instructions Review

Deployment to other process/ product:

Drawing
D8 Team and Individual Recognition:

Other:
Date Closed:

Responsible

Deployment description

Reported by:

D0 - Detailed symptom description as possible/available

Symptom Description:

Pictures:
Good Part

Trend Chart
Pareto

Bad Part

D2 - Problem Description
Problem Statement
Problem
Description

Object

WHEN

WHERE

WHAT

Vehicle(s)
Part Number(s)

Defect
Mechanism of Failure
Noise Factors
Piece-to-Piece
Change over Time
Customer Usage Cycle
External Environment
Neighboring System(s)

On Vehicle or
Object
First Observed
& Seen Since
First Observed
& Seen Since
Pattern Since

HOW BIG

In Process
Operating Cycle
Life Cycle

Magnitude
Defects per
Object
Trend
Hazard Plot(s)

IS

Logically could be but

IS NOT

Get
Information

D2 -Process Flow Chart

Show the workstation where the bad part was created.

Show the Workstation where the bad would be detected.

Show the Workstation where the bad would be detected.

D0 - Emergency action data

D3 - Interim Containment data
Parts localization
FORD Plant (warehouse)
FORD Plant (assembly line)
Transit
Supplier Ware house
Supplier Assembly line
Supplier Segregation area
Supplier Lab
Others

G8D

Number of
parts verified

Number of
bad parts

Identificant
ion of
good parts

Respons.

Total parts
reworked

Total
Scrapped

D0
D0
D0
D3
D3
D3
D3
D3

Rework standard description (if applicable):

Alert# (if applicable):

Observation:

Selection
Date

Date

Respons.

D3 - Interim Containment Action

Test / Analysis

Verification Method

Spec

Verification

MSA (if
applicable)

Test Result

If applicable, please insert pictures:

D3 - Interim Containment Action

Indicator

Before implementation

After implementation

Validation
% Improvement

Respons.

Date

D4- Fishbone (occurrence, no detection and system failure)

Machine

People

Material

X1 ...Xn

X1 ...Xn

X1 ...Xn
X1-Composio da MP-PP (pea falhada x pea
que no deformou (veculo Anderson)
X2-Uso material - HDT PP utilizado x aplicao

Y=Effect

X1 ...Xn

X1 ...Xn

X1 ...Xn

Mother Nature

Method

Measurements

D4- Potential Causes - Analyzes (occurrence, no detection and system fail)

X

X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X..

Potential Root Cause

Description

Analysis/Test

Method

Sample
Size

Spec

Result/
Evidence
(Good part )

Result/
Evidence
(Rejected
part)

Date
Start

Close

Respons.

MSA
(if
applicable)

Potential Root Cause

discarded/ Maintained

D4 - 5 Whys Study
Define symptom
Use this path for
the specific

Why did it OCCUR?

nonconformance
being investigated

WHY?

Therefore

Root cause

WHY?

Therefore

Use this path to investigate

why the problem was not
detected
WHY?

Therefore

Why wasn't it detected?

What existing control did not
detect it?
WHY?

Therefore

WHY?

Therefore

WHY?

Problem definition

Therefore

Use this path to investigate

the systemic root cause
(Quality System Failures)
WHY?

ROOT
CAUSE

Therefore

Why wasn't it Prevented?

WHY?

Therefore

WHY?

Therefore

B
WHY?

Therefore

WHY?

Therefore

WHY?

Therefore

D4 Questions
The defect was reproduced? If Yes, How, When, Who? If not, Why not?

The defect is systemic? Explain:

Why the defect occurred only in some parts and not in 100% of production? Explain:

What was the variable that allowed produce both good parts and bad parts? Explain.

The root cause is considered in FMEA and Control Plan?

What is the frequency of inspection of this characteristic?

If you reintroduce the bad part in your production/process/workstation, the part will be approved or rejected?

D5 - Permanent Potential Corrective Action (Ocurrence, Escape point )

X

Root cause

Verification analysis
method

Identified Corrective Action

Spec

Respons

Verification result
(method)

PCA
Validation
method

PCA
Validation
result

Date of the good

Parts at Ford
Plant

D6 - Permanent Corrective Action Implementation (Ocurrence, Escape point)

Corrective Action

Implementation date
planned

Respons

Implementation
Date

MSA (if
applicable)

Critical X
Critical X

Before

Process Validation
After

Status (G,Y
R)

Workstation
analisys

Date

Batch

Training
Versatality

Date

Batch

Acceptable
Criteria

Date

Date

Batch

Error proof

Date

Process Validation
Reaction
Plan

Date

Batch

Replication/
Containment

Date

Batch

Process
Improvement

Batch

Batch