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8D - Problem Solving

Quality Report Number : Quality Report Date : Challan Number :

Supplier / Line Title : Any other Traceability (If) :

Part Description : Part No : Repeat


Issue Reported
Completed By : Authorized By : 1st Time

D1 - Problem Solving Team


Name Function & Designation E-mail Contact Number

D2 - Problem description & details


What : Defect description

Why : Reason for Rejection

When : Date & Shift of rejection

Where : Incoming/Line/Warranty

Howmany: Rejection in Nos

Who : Reporter & Receiver name


Other Comments: Photo:

( Attach sketch /
data for details
where required )

D3 - Containment Action / Immediate action


Disposition Process ( Eg.,Method of Verification Identification on
Lot disposition Disposition Area Date OK Not OK
segregation/rework / Scrap) (inspection if any) Ok part

Sent Back Incoming / Stores

Scrap Assly Line / Mfg Line

Rework Final insp / PDI

Segregation Field (Warranty)

Deviation supplier Line

Others Supplier Finish Goods

D4 - Root Cause analysis - ( write the Possible causes) ( 3 Legged 5 Why Analysis)
a) What is the Specific Cause ? How it is produced ?
WHY WHY WHY WHY WHY

b) what is Detection Cause ? How it is escaped from the detection process ?


WHY WHY WHY WHY WHY

c ) What is the Systemic Cause ? Previously not identified / No such System / any Organization Flaw
WHY WHY WHY WHY WHY

d) Verification of identified Rootcause : Attach detailed analysis

Sl. No Major causes identified Simulation of the Problem Method of Simulation Target Responsibility Simulation Results Is this a rootcause

8D Problem Solving Form Page: 1 of 2


8D - Problem Solving
Quality Report Number : Quality Report Date : Challan Number :

D5 - Corrective Actions Plan & implementation - To prevent Reoccurrence ; Attach photos


Spe/Det/ Implementation
Sr. No. Major causes identified Present Method / Control Proposed Corrective action Resp Target
Sys date

D5A - Error & Mistake Proof Implementation - To prevent Reoccurrence ; Attach photos
Spe/Det/ Implementation
Sr. No. Major causes identified Present Method / Control Proposed Corrective action Resp Target
Sys date

D6 - Horizontal Deployment - Identify the Similar Product / Line / Process & implement the same corrective Actions
Sl. No Similar Area Action Plan Responsibility Target Date Comp. On

D7 - Process Document Review & Update ; Attach Documents


Operator Instruction DFMEA Packaging Instruction / Packaging slip Others

Inprocess Inspection Checklist Process Flow Engineering Drawing

Final Inspection Checklist PFMEA Special characteristics list

Process sheet Control Plan Fixture / assly drawing

All the modified Documents should be attached with the 8D

For Supplier
Comments: Name :

Signature :
Date :

D8 - Validation & Effectiveness Monitoring By Customer


Validation Resp Date Remark

1 Horizontal communication / Action on Similar parts

2 Audit of countermeasures

3 Review of Procedures / List / Documents changed

4 Review of sustenance of Actions

Defect Monitoring Reported Month Next month Second Month Third month

PPM or No.Of.defectives

Conclusion :

Reviewed By
Name : Comments 8D closure Status

Signature :

Date :

8D Problem Solving Form Page: 2 of 2