Tracking Number: ‘Customer! Machine: Response Due Date: i | 8D Problem Solving Worksheet - Long Form LY Status Step 0 41 2 3 4 5 6 7 8 tic Prepare | Team Describe | Cor Diagnose | Solve Validate | Prevent | Wrap Registered problem and Long Term Corrective Long Term Corrective Long Term Corrective Short Term Corrective | Action developed but not | Action implemented ‘Action confirmed effective. Action in place in house. implemented, Monitoring/evaluating Problem closed. effectiveness Prepare for Problem Solving -_| Is an Emergency Response Action Needed? baste problem waranUrequire an 8D? |__| (lf needed document actions in Action Item Table) 0 | so comment why and proceed, Assemble Team -€stablisha small | 7am Goals: group of people with the process/product knowledge, allocated time, authority and skill te Objecti 1 in the required technical disciplines to solve | '®4m Objectives: the problem and implement corrective actions. Name (Team Leader First) Describe Problem - Provide the starting point for solving the problem or noneonformance issue. ‘Sketch of Problem 2A. | Need to have ‘correct’ problem description to identify causes. Need lo use terms thal are understood by all Part Number(s)/ Process: ‘Customer(s)/ Machine: List all of the ie data and documents that might help you to define the problem more exactly? is there an action plan to collect additional information?2B Is IS NOT Who is affected by tha problem? Who first observed the problem? Who is not affected by the problem? Who did nat find the problem? 2 | internavextemal = To whom was the problem reported? What type of problem is it? What does not have the problem? ‘What has the problem? What could be happening but is not? 5 | Whatis happoning? What could be the problem but is not? Do we have physical evidence of the problem in our possession? Why's this a problem? Why is nota problem? B | |stho process where the problem occurred S| stable? Where was the problem observed? Where could the problem be located but is not? 2 3 Where does the problem occur? Where else could the problem be located but is. & not? = When was the problem first noticed? When could the problem have been noticed but © was not? 5 | When has itbeen noticed since? = How Muchy Many How Often ‘Quantity of problem? How Much is the problem causing in dollars, people, & Time? What is the trend (continuous, random, cyclical)? Has the problem occurred previously? How many could have the problem but don't? How big could the problem be but is not? ‘What could the trend be but is not? 2c Problem Description - combine the relevant information, this will be your Problem DescriptionInterim Containment Actions - Temporary actions to contain the problem and “fix 3 until permanent correction is in place. (Note: Validate that the action taken works). Document Actions in the Action Item Table Diagnose Root Cause - Analyze for “Root Cause” of the problem. Identify and verity the Escape Point 4A Brainstorm the possible causes of the problem (attach) 4A | Cause and Effect Diagram (atacn copy of complete diagram(s) as appropriate) How made/operated? Why did it get out/ fail? People Materials/info Machine Problem (effect) People —_Materials/Info Machine Method — Environment Measurement Method Environment Measurement Note on Diagram(s) circle the most likely contributors (3 max) from each side. 4B | 5-Why Analysis ‘Ask — Why did this happen? Ask - Why did this happen? Ask - Why did this happen? Ask - Why did this happen? Ask - Why did this happen?Identify Solutions - solutions that address and correct the root cause. Solutions determined to be the best of all the alternatives. Document and verify the Permanent Corrective Action (PCA) in the Action Item Table. Validation - implement and validate to ensure that corrective action does “what itis supposed! to 6 do.” Detect any undesirable side effects. Document this on the Action Item Table. Retum to root cause analysis, if necessary. Prevention (Design / Information Systems Review) - Determine what improvements in 7 systems and processes would prevent problem from recurring. Ensure that corrective action remains in place and successful. 7A Address Similar Systems - tist simiar systems. Assign Action Item and Individual to Follow Up to correct products/ machine with the potential for the same defect. Product! Machine / Process / Action Assignee7B Cheek if Applicable Review the following documents / systems. Document Assignee Completion Date Planned Actual Control Plans Engineering Master Specifications Manufacturing Set-up Sheet Manufacturing Check Sheet(s) QA Inspection Work Instructions QA Inspection Forms PM Procedure(s) vob Descriptions(s) Job Certifications! Recertify 8 Congratulate Your Team! - use ail forms of employee recognition and document as necessary. Celebrate successful conclusion of the problem solving effort. Formally disengage the team and return to normal duties. Was the Problem Solving Worksheet Effective? YesiNo Signature/Title DateAction Item Table ‘Retions Implement and Verify Actions Ration Containmenl Corrective How ton] Fault tem menu Ci verity | Hows | Action Assign Planned | Actual | Status Rogisered problem and Short Tom | Lgrig Fem Conectve Acton Long Term Corrective Action Long Term Corrective Action Cortecive Acton n place inhouse. | Geveiopad but notimplomerted. | implemented, Montxinglovalvating | contmed effective, Prablom dosed toctivenats, ‘Note: Copy this page and attach as often as necessary