Instructions and Guidelines for Tenneco 8D Problem Solving Workbook
P06_23_7_2B.xls
This workbook and its attachments are required to be used for
any Customer External Issue UNLESS Customer formatted templates are dictated,
When Customer formatted templates are dictated - if they are not comparable or missing any required elements of this workbook - the Tenneco workbook
elements) are required to be completed in addition to the Customer documentation for Tenneco documentation and records.
Tab Color Coding
Required Element
Optional - but strongly If any optional tab tool is not utilized: 1) Remove the tab 2) The information is expected to reside
Recommended within the 8D tab
At minimum one of such Delete RC identification tab
tabs must be used tool(s) not used
GENERAL COMMENTS:
1) Any Pictures be sure they are BIT MAPS or Enhanced Meta Files. (DO NOT IMPORT JPEGS, GIFFS, TIFFs,…)
2) Any additional referred to attachments in the body of the 8D should be made tab attachments (IDENTIFIED as they are in the 8D when ever possible).
1) Any Pictures be sure they are BIT MAPS or Enhanced Meta Files. (DO NOT IMPORT JPEGS, GIFFS, TIFFs,…)
2) Any additional referred to attachments in the body of the 8D should be made tab attachments (IDENTIFIED as they are in the 8D when ever possible).
ook
- the Tenneco workbook
d records.
xpected to reside
b
8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
(1A) Team Contact (2) PROBLEM DESCRIPTION (all Background Symptom details): Photo(s) /Sketch/Prin
In this section please explain in a series of statements or bullets:
Team Lead: Who Found - What was found - How was it found- Where was it found - When was it found:
Phone: How Many/Frequency/ any Pattern: - Prior History or Background:- Anything else to understand the issue
Dept/Activity: for proper containment and to understand root cause:
Champion:
Phone:
Dept/Activity:
(1B) Status
Date Opened:
Status Date:
Next Status Due Date:
Status:
(IP- In Progress;
VP- Verification Period;
C-Closed)
(1C) System/PN
TEN System/PN:
Customer System/PN:
(1D) Concern Initiator
Name:
Phone:
Dept/Activity:
2A) Problem Statement (Requirement (expectation) vs actual condition - Quantify
Is this a Repeat? (Yes or No):
If Yes: 8D previous report numbers for reference are:
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8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
(3) EMERGENCY RESPONSE and CONTAINMENT ACTIONS DATE VERIFICATION
ACTION(S): Include emergency actions (For Product related - All existing material and material to be produced must have METHODS
containment actions until issue PCA is verified ) Assignee TARGET COMPLETE (Documented WI and ID Markings)
(4) ROOT CAUSES Fishbone Diagram Attached: Y/N Is / Is not Diagram Attached: Y/N 5 Why's Diagram (REQUIRED)
CAUSE(S) FOR OCCURRENCE: Method of Root Cause V
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8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
CAUSE(S) FOR ESCAPE:
(5) CORRECTIVE ACTIONS (6) VERIFICATION
DATE
INTERIM CORRECTIVE ACTIONS: RESPONSIBILITY TARGET COMPLETED METHODS
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8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
PERMANENT CORRECTIVE ACTIONS:
Must address all verified Occurrence and Escape factors RESPONSIBILITY TARGET COMPLETED METHODS
(7) PREVENTION (6) VERIFICATION
DATE
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8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
RESPONSIBILITY TARGET Complete METHODS
Must Address All: (1- Systemic findings (L3 of 5Y); 2 - like and similar at site; 3 - applicability to
outside location site)
1) Systemic: L3:
2) Inter Plant Like and Similar:
3) Lessons Learned Actions and Read Across (Intra Plant):
(8A) TEAM MEMBERS
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8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
(8B) Reviews and Approvals - Names-Titles-Dates
Local Reviews (Always Required) Signatures mean approval Corporate Reviews (Mandatory for Corp. Issues)
Operations Management
Quality Representative
Quality Management
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Photo(s) /Sketch/Print Section:
Is this a Repeat? (Yes or No):
If Yes: 8D previous report numbers for reference are:
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VERIFICATION
RESULTS
Method of Root Cause Verification
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RESULTS
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RESULTS
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RESULTS
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Tenneco 3-Legged 5 Why Analysis
Concern number: Date of issue: Site/Location:
Part / Process:
Permanent Corrective Actions Timing
Therefore
Insert Issue Description
Specific/Occurrence
Therefore
Why
Therefore
Why
Insert Issue Description Therefore Therefore
from above again
Detection Why
Therefore Therefore
Why Why
Therefore Therefore
Why Why
Insert Last box of Root Therefore Therefore
Cause Occurrence
Systemic Why Root Cause
Therefore Therefore
Why Why
Therefore Therefore
Why Why
Therefore
Why Root Cause
Therefore
Why
Therefore
Why
Tips: Insert photos where needed to show
conditions describing,
Additional legs may be required if
independent factors identified. (refer to
example)
Root Cause
Read Across Actions Timing Lessons Learned Summary
8D Document Audit 8D #__________________
Yes No
D1 Form the Team
1.1 Is the team cross functional?
1.2 Does the team member list contain full names and titles?
1.3 Does the team include hourly/production employees ?
1.4
Is the leader from the appropriate functional area, or is the primary functional
area represented ?
D2 Describe the Issue
2.1
Does the problem statement tell what, who, where, when, why, how many and
how often?
2.2 Does the problem statement avoid predicting cause (Spec vs Condition) ?
2.3
If applicable does the problem statement include Customer and TEN part number
?
D3 Containment Activities
3.1 Was responsibility for containment assigned to the process owner ?
3.2
Is containment activity defined (formally documented) WI for methods and
marking of material, (including dates and status) ?
3.3
Are results documented including number of inspections/number of non
conformances found ?
3.4
Have all inventory points been considered (e.g. transit, salvage, WIP, etc) and
current production until issue resolved?
Find and Verify Root Cause Both Occurrence and Escape
D4
4.1
Did team utilize root cause analysis tools (5 Why, Fishbone) to determine root
cause?
4.2
Was ‘5 Why’ done correctly? Does it branch where necessary, does each ‘Why’
derive directly from the previous ‘Why’?
4.3 Is the Fishbone Diagram complete and does it pull from the FMEA?
4.4 Has it happened before? If yes, why did it fail again - documented?
D5 Corrective Actions
5.1 Was corrective action selection based on data showing a link to the issue?
5.2
Is there a documented implementation plan (including responsibility, timeline, and
completion date)?
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8D Document Audit 8D #__________________
Yes No
5.3
Have all root cause factors (occurrence and escape) identified been accounted
for in the actions?
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8D Document Audit 8D #__________________
Yes No
D6 Verification of Corrective Action
6.1
Is there documented verification that corrective actions were effective (trend
charts, test results, process capability, etc.) including date of verification?
D7 Prevent Recurrence
Were actions taken to prevent recurrence including updating of process
7.1 documentation? (Standard Work, Product/Process Specs, FMEA, Control Plan,
etc.)
7.2
Were similar internal products and processes investigated and corrections
implemented to prevent failures? (has it been institutionalized)
7.3
Was applicability for external lessons learn read across out side the site been
addressed?
D8 Congratulate the Team
AUDIT COMPLETED BY
Auditor__________________ Date: ___________________
Auditor__________________ Date: ___________________
Auditor__________________ Date: ___________________
Comments/Feedback section
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N/A
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N/A
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N/A
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FISHBONE (ROOT CAUSE FACTORS)
LIST ALL POSSIBILITIES IDENTIFIED THROUGH BRAINSTORMING OR WHATEVER MECHANISM TO GENERATE POTENTIALS
Denote factors with (O) - Occurrence (E) -Escape or do separate fishbone for each
Man Machine (Tooling) Environment
INSERT
FAILURE
MODE
Method (Process) Material Measurement
Test Direct ü ? cross-out
Cause: True (VERIFIED) Cause Possible Cause RULED OUT - Not a Cause
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"IS" "IS NOT" TABLE (Filtering to the vital few)
Non-Conformance: Insert failure Mode
A B C
"IS" "IS NOT" Insert Brainstorming Topic
What?
Where?
When?
How Much (frequency-size…)
??? - Brainstorming or Fishbone
Element Potential?
Insert as many sections to the table as is needed:
Filtering Problem Description Symptom Background information:
Filtering Fishbone/Brainstorming Factors
Take each topic and put it in "C"
If a given "C" fits the criteria of every A and B Mark it on the Fishbone as
a leading potential cause.
If a given "C" doesn't fits one criteria of "any " A or B CROSS IT OUT/
"Strikethrough" on the Fishbone
PLEASE FIND A STEP-BY-STEP GUIDE TO USE THE X/Y DIAGRAM
GO
GO TO
TO GUIDE
GUIDE
Return
Return to
to YX
YX Diagram
Diagram
Return
Return to
to YX
YX Diagram
Diagram
If a Fishbone or "Is / Is Not" root cause identification tool
is not used insert evidence to this tab of what root cause
identification tool activity was used.
If your issue also has an action matrix please repla
with your action matrix.
x please replace this tab
atrix.
For Product related Issues - Cleaning the Pipeline:
Certified Product Identification
Suspect Qty (by PN) Certification Method Method
Location (Skid, Trailers, Lot codes and Quantities) (Refer to document or detail here) Fall out Qty (Pic and alerts are best)
Customer
Locations
In transit
Finished Goods
Final Assembly
Sub Assembly
Component stock
Supplier Transit
Supplier Stock
Outside
Processing
Rework
Locations
Service
Inventory
8D - Document Update Checklist
Potential Documents Requiring Not Req'd If Req'd Training
updates Document (ID) Numbers Assignee (owner) (Place "X" in Completion Completion Explanation if required
(Note list may not be all inclusive) box) Date Date
PPAP
Process Flow
PFMEA
Control Plan
Work Instructions
Standardized Work
Travelers/Routers
In Process Checksheets and
Inspection forms
DFMEA
Standards or Masters
Prints/Specifications/Test
Methods…
PROCESS change Approvals
Other
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