8d corrective action root cause

8/20/2019 8D Corrective Action Root Cause

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© 2013 Eaton, All Rights Reserved.

8D Corrective Action & Root Cause Analysis


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© 2012 Eaton Corporation. All rights reserved.

Overview of 8D

Definitions

Review of 8D steps

Review of examples of 5-Why

Questions

Aen!a


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"rainin #roun! Rules

Please interrupt and ask questions at any time

Please turn o your !ell phones

"# $#% pla!e your phone on hold at any time

Please mute your phone i possi&le to minimi'e noise

(et us kno) i you lose the )e&inar s!reen during the presentation

Please share personal e*perien!es and questions throughout the training

+ou )ill get a !opy o this training or reeren!e


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What is 8D

-" is a stru!tured !orre!tive a!tion pro!ess -" stands or the Eight

"is!iplines o Pro&lem /olving

Root Cause AnalysisRCA is an integral part o the -" pro!ess

%his session )ill

"eine -"

"emonstrate -" pro!ess

%rain in Root Cause Analysis 4hy5s

#&6e!tives o this training +ou )ill &e!ome amiliar )ith the -" steps

+ou )ill &e!ome more proi!ient at Root Cause Analysis using 4hy5s


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$oca%ulary

Containment 7 A!tions taken to isolate the pro&lem rom any internal8e*ternal!ustomer. 9sually e*pe!ted to &e !ompleted )ithin a 2hr 7 - hour period.

Corrective Action 7 %he a!tion taken to eliminate the !ause o the

non!onormity.

rror proofin 7 4hen a pro!ess is designed to prevent an error rom

o!!urring.

'reventive Action 7 %he a!tion that is taken to eliminate !onditions that !ould

produ!e a non!onormity.

Root Cause 7 At its simplest orm, you !an turn o and on the pro&lem in a

!ontrolled environment. %he root !ause should e*plain 100: o the un)anted

pro&lem8dee!t and that there are no additional reasons that the pro&lem e*ists.


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Definition ( 'reventive Action

'reventive Action is the a!tion taken to eliminate the !onditions that could produce a non!onormity.


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8D ( iht Disciplines to 'ro%lem ,olvin

8D* )hi!h )as initiated in the automotive industry, is a stru!tured pro&lemsolving method or produ!t and pro!ess improvement.

8D is short or 8 Disciplines.

The steps do not all start with “D”

8D is stru!tured in - steps and emphasi'es

Team problem solving

=ord5s %eam #riented Pro&lem /olving /"O',0 systems )as the pre!ursor to

8D

"eam wor1 an! not s1ippin steps is critical222


8/95-© 2013 Eaton, All Rights Reserved.

,teps in an 8D

%he steps in -"• "@1 sta%lish the team

• "@2 Define the pro&lem

• "@3 "a1e ,hort "erm Action Containment

• "@ Determine Root Cause

• "@ Develop3$erify Corre!tive A!tion

• "@; )mplement3$ali!ate Corre!tive A!tion• "@? 'revent Re!urren!e8/hare the /olution

• "@- Reconi4e the %eam

Day

67 ( 78hrs

6 wee1s

9 !ays


9/95© 2013 Eaton, All Rights Reserved.

'u%lic :ocation of ;orm

/upplier Bnormation -"

http://www.cooperindustries.com/content/public/en/power_systems/resources/library/supplier_information.htmlhttp://www.cooperindustries.com/content/public/en/power_systems/resources/library/supplier_information.html



xample of 8D ;orm

"he form steps you throuh the 8D process



Chec1 your 1nowle!e

What !oes the D. in 8! stan! for<A+ Deree

=+ Discipline

C+ Deci!e!ly =a!

The correct answer is B – Disciplines. -" stands or the Eight"is!iplines o Pro&lem /olving



Chec1 your 1nowle!e

"ypically how lon is the containment phase

of an 8D<A+ 67 ( 78 hours

=+ 6 wee1s

C+ 9 !ays

D+ As lon as it ta1es

The correct answer is A – Containment is typically expected tobe completed within the frst 24 – 48 hours ater you ha!e

recei!ed notifcation that a deect has been produced.



Chec1 your 1nowle!e

"ypically what is the expecte! time to

complete an! close the 8-D<A+ 67 ( 78 hours

=+ 6 wee1s

C+ 9 !ays

D+ As lon as it ta1es

The correct answer is c – Closure is typically re"uired within #$days o the initial notifcation. This means that a root cause hasbeen selected and the problem was able to be turned on and

o%. &inal !erifcation may 'o on past #$ days dependin' on thesituation.



D sta%lish "he "eam

A!!itional ta%s are availa%le in the form for reference


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8D ( sta%lish "eam /D>0

Typically the Quality Manager will assign the person

responsible to lead the corrective action. That Team

Leader will then select the team members.

The Team should include all functions with

knowledge of the problem (including “process

owner”.

Team Leader or Quality Manager should train team

members as needed! but leading the team through

the process is the best form of training.


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D Chec1list

D? sta%lish the "eam

Che!klist Are the people ae!ted &y the pro&lem represented

"oes ea!h individual have a reason or &eing on the team

Bs the team large enough to in!lude all ne!essary input, &ut

small enough to a!t ee!tively

4ho is designated Champion

4ho is team leader

Are all team mem&ers responsi&ility5s !lear


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1?© 2013 Eaton, All Rights Reserved.

Chec1 your 1nowle!e

What functions are typically on the 8D team<A+ Quality

=+ nineerin

C+ @anufacturin

D+ 'rocess Owner

+ All of the a%ove

The correct answer is ( – &or best results 8D teams are cross)unctional in nature* not e!ery team will need e!ery unction*but the ob+ecti!e is not to ma,e it a one man or one unction

e!ent.


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1-© 2013 Eaton, All Rights Reserved.

,teps in an 8D






• "@; )mplement3$ali!ate Corre!tive A!tion• "@? 'revent Re!urren!e8/hare the /olution


Day

67 ( 78hrs

6 wee1s

9 !ays


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D6 Define the 'ro%lem

se pictures when they are availa%le


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8D ( Define 'ro%lem /D>60

Pro&lem "einition is a positive statementthat des!ri&es the Dpain

Food "einition is !riti!al to determining Root Cause

Ans)ers 7W6B 7 Who, What, When, Where, How, How Many

D4hy is not part o Pro&lem "einition this is ans)ered in Root Cause Analysis G RCA

Food "einition does not pla!e &lame

Avoids suggesting solutions DPro&lem happened due toH, or D(a!k oadhesive resulted inH

Define what is or what is not


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8D ( 'ro%lem Definition /D>60

%ake the time to !learly deine the pro&lem, )ith a!ts.

Food Pro&lem "einition is the spring&oard to asking theright questions on RCA 4hy, 4hy, 4hy,H

Poor Pro&lem "einition leads to symptom resolutionrather than Root Cause /olution

DBs8Bs $ot is a good method or Clear and Con!isePro&lem "einitions.

B Dla!k o, Dinsui!ient, Ddue toH are in your Pro&lem"einitionHyour team is in trouble!


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8D ( 'ro%lem Definitions? #oo! or =a!<

D(a!k o parts !aused 10: miss in sales or >ay.

Bad – Assumes ause o problem

D>arketing delays !aused pro6e!ts to &e 2 months

overdue on average.

Bad – "laes blame and assumes ause

DBmpulse test !oil ailures or all 3 phase transormers at

Iadger "r in!reased rom 10,000 ppm in J1 to 1,000

ppm in J2.

Good – Answers #W$H

Research it first* only recor! the facts2


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D6 Chec1list

D6? Descri%e the pro%lem

Che!klist4hat type o pro&lem is it

Can )e list any resour!es and do!uments )hi!h might &etter quantiythis pro&lem

Bs there any eviden!e this pro&lem has sura!ed &eore

4hat is the e*tent o the pro&lem

Kas the pro&lem &een in!reasing, de!reasing or remaining !onstant

"o )e have physi!al eviden!e o the pro&lem in hand

Kave ailed parts &een analy'ed in detail

Bs there an a!tion plan to !olle!t additional data i needed

"o )e have the right team mem&ers to pro!eed to the ne*t step


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Chec1 your 1nowle!e

What !oes 7W6B stan! for<A+ 7 Ways to han!le

=+ Why* What* When* Who* Bow* Bow @any

C+ Who* What* When* Where* Bow* Bow @any

D+ ;or wor1ers to help

The correct answer is C – -ho ound the deect* -hat was thedeect* -hen was the deect detected* -here was the deectoundlocated* /ow was the deect ound* and /ow 0any units

were deecti!e1 -hy is not part o the e"uation in tep 3Defnin' the problem. -hy comes in durin' the root cause

analysis sta'e.


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Chec1 your 1nowle!e

A oo! pro%lem !escription< /select all that apply0A+ Assins %lame

=+ )s %ase! on facts

C+ ,uests solutions

D+ 'ositively !escri%es the pain.

The correct answer is B and D – 5roblem descriptions detail theissue in a positi!e* act)based way* without assi'nin' blame orsu''estin' solutions.


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,teps in an 8D






•"@; )mplement3$ali!ate Corre!tive A!tion

• "@? 'revent Re!urren!e8/hare the /olution


Day

67 ( 78hrs

6 wee1s

9 !ays


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D "a1e ,hort "erm Action

Di! you et all of them ( )nclu!e parts at ,up-,uppliers<


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8D ( Contain 'ro%lem /D>0

Containing the pro&lem and Prote!ting the Customer musto!!ur immediately+ 67hrs is the industry norm or

!ontainment a!tions to take pla!e. @ax of 78.

"etermine the s!ope time period, material lot num&ers,

parts ae!ted, et!

Produ!tion and8or /hipping Kold to &e implemented

-" system is used to report8tra!k Kolds and Containments

DBron 4all is a orm o Containment Prevent pro&lems

rom shipping to Customers


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Definition - Containment

Containment is the systematic search andquarantine o suspe!ted non!onorming produ!t

throughout the supply8delivery !hain. 4arehouse,

in pro!ess shelves, supplier sto!k, H >ake sure

you get it all.

Bn our Containment step )e also in!lude a pro!ess

to determine i it5s ne!essary to notiy !ustomers in

the orm o a re!all, advisory or other

!ommuni!ation.

Di! you et all of them<


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Definition - Containment

Containment is more than 6ust getting all the!urrent produ!t !ontained.

%his step also in!ludes )hat used to &e !alled

D/hort %erm Corre!tive A!tion.

%his !ould &e sorting, layered inspe!tion or re)ork.

>ake sure that implementation o the !ontainmenta!tion )ill not !reate other pro&lems i.e., part

shortages or un!he!ked re)ork.

Bt also has to last until the permanent Corre!tive

A!tion is in pla!e.

What can you !o until the 'ermanent Corrective Action is in place<


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D Chec1list

D? Contain the 'ro%lem

Chec1list?4hat !ontainment a!tions have &een identiied =or Parts in sto!k, Parts Bn

transit, Parts at the supplier lo!ation, Parts in pro!ess at the operators )ork

station, Parts at the Customer lo!ation

Kave all quantities &een a!!ounted or and quarantined until disposition !an&e made %& 'A(&)*+ that they do not end up &a!k in sto!k

Kave )e ensured that implementation o the !ontainment a!tion )ill not

!reate other pro&lems i.e. part shortages, un!he!ked re)ork.

4ill interim a!tions last long enough until the Corre!tive A!tions are in

pla!e

Are responsi&ilities or !ontainment a!tions !lear

4hen )ill the !ontainment a!tions &e !omplete

Kave the !ontainment a!tions &een do!umented

"o )e have the right team mem&ers to pro!eed to the ne*t step


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67 - 78 Bours to Contain the 'ro%lem

Containment is reuire! with in 67 - 78 hrs+

Once the ,upplier Corrective Action /,CA0 is entere! into our !ata%ase /Q-

':,0 you will et notification an! remin!ers via e-mail+


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Chec1 your 1nowle!e

What !oes containment mean<A+ A systematic search an! uarantine of suspecte!

nonconformin pro!uct throuhout the

supply3!elivery chain+

=+ ,toppin the !efect from %ein pro!uce!C+ 'urin the !efect from the warehouse

D+ Recallin all potentially !efective items

The best answer is A – Containment is a systematic search and"uarantine o suspected nonconormin' product throu'hout the

supplydeli!ery chain.


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Chec1 your 1nowle!e

Bow lon !oes containment nee! to %e in

place<A+ 67 ( 78 hours

=+ in!efinitely

C+ ntil corrective action is implemente!

D+ 9 !ays

The correct answer is C – Containment starts within 24 – 48hours o problem notifcation* but remains in e%ect until a

permanent correcti!e action is implemented* ensurin' the trueroot causes o the deect has been corrected.


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,teps in an 8D



• "@3 "a1e ,hort "erm Action Containment• "@ Determine Root Cause





Day

67 ( 78hrs

6 wee1s

9 !ays


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As1? Bow !i! the pro%lem occur<

Why< E+

Why< E+

Why< E+

Why< E+Why F the true root cause /typically0

Detection an! Occurrence

As1? Bow was it misse!<

Why< E+

Why< E+

Why< E+

Why< E+Why F what controls nee! to %e in place toprevent another escape

When i!entifyin root cause the team shoul! focus on why the issue

occurre! first* an! then secon!ly on how the !efect was misse!+"herefore you !o your 5 Why analysis on %oth pieces of the failure mo!e+


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D7 Determine3$erify the Root Cause

Wor1 throuh the pro%lem* use your team an! !onGt s1ip steps2

2CA Template


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8D ( Root Cause Analysis /RCA0

"he C',D ,CA form inclu!es a 5Why analysistemplate as well as =rainstormin. an!

Cause3ffect. !iarams+

Other techniues /'rocess @ap* DO* Anova* 'areto*

etc+0 are also tools to ai! in RCA+

"he C',D 8D process inclu!es ,CA for? Occurrence /Why !i! the pro%lem occur


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8D ( Root Cause Analysis /D>70

"here are many techniues to !etermine Root

Cause

As1in Why< 5 times is the simplest an! most

powerful RCA techniue+

"his is a simple process that is freuently !one

poorly+ "he first Why starts !irectly from the 'ro%lem

Definition? Why !i! the pro%lem occur as

state!


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8D ( Root Cause Analysis /D>70

RCA is the Beart an! ,oul of the Corrective Actionprocess

"here may %e multiple contributing causes %ut there is

only one

"rue Root Cause

Actions shoul! %e ta1en to a!!ress the contributing

causes if appropriateE

=utI The Root Cause must be eliminated

orEthe problem will return!


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Definition ( Root Cause /RC0

"he Root Cause is the most %asic reason for a pro%lem or!efect+ If this cause is eliminated, the problem would

not occur

)f the cause of a pro%lem is operator error.* thatGs not the

real Root Cause+ "he Root Cause is more li1ely that theprocess is not rror 'roofe!.+

Correctie "ctions must address the Root Cause if the

problem is to be eliminated

Jou will 1now it is the Root Cause if you can turn the pro%lem off an! on


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Root Cause

)mme!iate causes are KO" root causes+ "ypical imme!iatecauses you may see on Corrective Action reports are?

#perator $rror

%ailure to %ollow &rocedures'wor( instructions

Inspection not recorded by the operator

Gage )ot turned in for calibration

#perator not trained

Inadertent omission

"hese are KO" root causes* they may %e a contri%utin cause %ut not the

true root cause2


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Root Cause

Root causes are wea(nesses *ineffectie processes or controls+ in the system that cause

or allow *fail to preent+ errors and

nonconformances

ffective corrective action will 'R$K"

recurrence or RDC "B ;RQKCJ of

occurrence+


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Root Cause"orrective #ction that addresses only the

immediate cause will $%T prevent recurrence.&'ample

$onconformance )unctional gage past due for

calibration.*mmediate cause Quality #ssurance did not

calibrate the gage before the due date.

"orrective #ction "alibrate the functional gage

(fi'es the immediate problem only


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Chec1 your 1nowle!e

What are the two areas of the 'ro%lem that

the team wants to focus on !urin RCA<A+ Detection an! Occurrence

=+ ,everity an! Occurrence

C+ Detection an! ,everity

The correct answer is a – Detection and 6ccurrence. -hy didthe issue occur and why was it not detected.


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Chec1 your 1nowle!e

All of the followin are examples of

imme!iate root causes except<A+ Operator rror

=+ ;ailure to ;ollow Wor1 )nstructions

C+ se of expire! material

D+ #ae missin cali%ration stic1er

The correct answer is C – 7se o expired material may be anactual root cause or the fnal why o the -hys assessment.

The other items are symptoms o a systemic issue.


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?© 2013 Eaton, All Rights Reserved.

5 Why Review

+ ,hy


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-© 2013 Eaton, All Rights Reserved.

5 WhyGs

)f you continue to as1 Why< you will !iscover thesystemic pro%lem* rather than %ein satisfie! with fixin

a symptom+ ,ymptoms that come from contri%utin

causes

-eview + ,hye'ample


49/95


"he stone on the Lefferson @emorial was crum%lin

Why #1: Why was it crumbling?;reuent washins were wea1enin the stone+

Why #2: Why was it washed so often?

Why #3: Why are there so many bird droppings?

Why #4: Why were there so many spiders?

Why #5: So why were there so many midges?

"o remove the %ir! !roppins+

=ir!s were eatin the a%un!ant spi!ers there+

-olution. /elay turning on the spot lights until one hour after

sunset, by which time midge population is down 012 By doing

this, the food chain is bro(en and less frequent washings are

required

,pi!ers were attracte! to all the mi!es+

very evenin at !us1* mi!es emere in a matin fren4y+ At

this same time* 'ar1 ,ervices turns on its spotlihts* which

attracte! all of the mi!es+

"he 5 Whys


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5 Why5 WBJ,< Analysis

4hys Analysis !onsists o team mem&ers identiying a possi&le root !ause &y asking D4hy until the root !ause isun!overed. Bt may take more or less than ive 4hys %o get to the Root Cause )ive is typial in most ases

+et-s onsider the gage alibration nononormane illustrated on the C" and Root Cause tab.

Konconformance? ;unctional ae past !ue for cali%ration

4hy Fage %e!h did not !ali&rate the gage &eore the due date.

4hy Fage didn5t sho) up on the gage re!all list

4hy Cali&ration interval )as not entered on the gage master re!ord

4hy a. Fage %e!h didn5t kno) the interval )hen the gage )as entered in

the master list

&. Fage %e!h didn5t ollo) up to enter the interval later.

4hy Fage%rak does not or!e entry o the interval )hen entering gages in

the master list

Kow that a possi%le Root Cause has %een i!entifie!* enerate a solution* implement it an! chec1 for proof that itGs effective+


51/95


5 Why ,ummary

,hat if the team does not identify the -oot "ause

/ossibly the problem was not defined well.

/ossibly working on symptoms instead of the real problem

(problem definition0

/ossibly some of the “facts” are not true 1 confirm with data.

/ossibly the team doesn2t include the right people to fully

understand the problem.

/ossibly skipped a step or two! missing critical information 1

better to take “baby steps”.

Bow to et to the 5 Why if your not sure


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Bow to et to the 5 Why if your not sure

you have only one

#ather your team* i!entify the possi%le causes* select "op


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Kow %rea1 out the 5 Why

se one 5 Why wor1sheetfor each of the top

suspect causes


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5 Why Review

&ach response needs to be confirmed with data

Run experiments to confirm that the team’s response to each“why” is accurate.

Don’t allow a dominant team member to state a “fact” without

confirming it.

-ead the “why responses” from the bottom to the top of

the problem statement linking them with “therefore”. All responses should link logically backwards with the word

“therefore”.


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D7 Chec1list

D7- Define3$erify Root Cause

Chec1list?

• What sources3metho!s have %een use! to !etermine root cause<• Are all the potential cause! liste! in case at a future !ate you

nee! to refer %ac1 to them+

• Can the root cause explain all we 1now a%out the pro%lem!escription<

•Can the root cause %e turne! off an! on<

• Do we have the riht team mem%ers to procee! to the next step<


56/95


Chec1 your 1nowle!e

What are some reasons we miht not %e a%leto i!entify root cause< /Chec1 all that apply0

A+ ;acts. are not true or unconfirme!

=+ 'ro%lem statement not well !efine!

C+ Wor1in on symptoms only

D+ All of the a%ove

The correct answer is D – All o the abo!e. The problem

description needs to be accurately defned or the team can 'odown the wron' path. 6ne dominant team member may state

authoritati!ely 9acts: that remain unconfrmed* leadin' theteam to wor, on symptoms such as operator error or trainin'*

rather than 'ettin' to the systemic issue in play.


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Chec1 your 1nowle!e

Bow to you 1now when you have reache!true root cause< /Chec1 all that apply0

A+ Operator at fault has %een name!

=+ 'ro%lem can %e turne! on an! off

C+ "he selecte! cause explains all we 1now a%out theissue

D+ "he issue cannot %e recreate!

The correct answer is B and C – ;oot cause is loo,in' or the

reason the e!ent occurs* and when ound you should be able toturn the problem on and o% * thus explainin' all we ,now about

the issue.


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Call for =ac1up

)f you nee! help* please as1+ We are here to help2

We can assist in?

;acilitation

"rainin

Review

Korth American ,Q Contact


59/95


Korth American ,Q Contact

)nformation

Patti >orris/upplier Juality>anager CP/"

Charlette

>ueller %ransormers and

P"" /JE

Eugenia

Raigo'aJR# and P""

/JE

"ave Chovan

Ele!tri!al and EA//JE

%om Caravella

/)it!hgear and

PR" /JE

"esk 2;2G2G3;

"esk 2;2G2G21

"esk 1G?0G??"esk 1G?;-G-22"esk 011G2G2G211G311

Contact your =usiness nit-Division ,upplier Quality nineer with

uestions2


60/95

;0© 2013 Eaton, All Rights Reserved.

,teps in an 8D



• "@3 "a1e ,hort "erm Action Containment• "@ Determine Root Cause





Day

67 ( 78hrs

6 wee1s

9 !ays

D5 Develop 3$erify the Corrective


61/95


p y

Action

:ist specific action with specific owners an! specific !ates2


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8D ( Corrective Action /D>50

%nce the -oot "ause is found it2s usually clear

what the "orrective #ction needs to be. The "orrective #ction must address the -oot

"ause000 There may be multiple "orrective #ctions and

some actions may address "ontributing "auses

1 this will make your solution more robust incase other factors change in the future.

"orrective #ction for the problem itself

(%ccurrence plus the “3etection” issues need to

be implemented to address the full dimension of

the issue.

Closin contri%utin actions is a oo! thin2


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rror 'roofin

rror 'roofin comes from aLapanese term 'o1a Jo1e.+

"rue Corrective Actions result in

rror 'roofin . in the 'rocess orDesin to prevent similar pro%lems+

,uccessive layer Detection

/)nspection0 is a form of errorproofin+


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8D ( Corrective Action /D>50

“&rror /roofing” the process will accomplish both

"orrective #ction for the problem “%ccurrence” and

"orrective #ction for “3etection”.

&rror /roofing is an important tool that 4ustifies a separate

training session.

*f “-etrained the %perators” is the "orrective #ction! the

team hasn2t really found the -oot "ause and hasn2t

implemented a "orrective #ction that will prevent

recurrence.

Operator rror is not a true root cause2


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D5 Chec1list

D5 ,elect an! $erify the Corrective Action

Chec1list?

Can the action %e implemente!<

What ris1s are associate! with this choice an! how shoul!they %e manae!<

Will this create other pro%lems< What metho!s will %e use! to verify the effectiveness in the

short an! lon term<

Bave !ates %een set to verify the effectiveness<

Bas responsi%ility %een assine! to verify the short an! lonterm effectiveness<

What !o you plan to !o if this action !oes not satisfactorilysolve this pro%lem<

Do we have the riht team mem%ers to procee! to the nextstep<


66/95

;;© 2013 Eaton, All Rights Reserved.

Chec1 your 1nowle!e

When selectin a corrective action what mustit !o<

A+ =e implemente! within 67 hours

=+ A!!ress the root cause

C+ =e economicalD+ =e simple

The correct answer is B – The correcti!e action must address

the root cause.


67/95

;?© 2013 Eaton, All Rights Reserved.

Chec1 your 1nowle!e

What !oes the term 'o1e-Jo1e mean<A+ 'erfect

=+ A soft %oile! e

C+ rror-proof

D+ Defect free

The correct answer is C – (rror) proo* is the (n'lish translation

o the t means the partprocess hasbeen desi'ned to pre!ent deects rom bein' produced andor

escapin' the production cell.


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,teps in an 8D



•"@3 "a1e ,hort "erm Action Containment



•

"@; )mplement3$ali!ate Corre!tive A!tion• "@? 'revent Re!urren!e8/hare the /olution


Day

67 ( 78hrs

6 wee1s

9 !ays

DM ) l t 3$ li! t th C ti A ti


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DM )mplement 3$ali!ate the Corrective Action


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8D ( Corrective Action $erification

Bt5s ne!essary that )e Dmaintain the gain

%he Corre!tive A!tion has to address the Root Cause, so it5s important

that a ollo) up audit veriies that the Root Cause )as eliminatedM

/omeone )ith a vested interest )ho )as not part o the Corre!tive A!tion team is !hosen &y the Juality >anager to ollo) up.

Bn some !ases verii!ation should &e done soon ater implementation

and again ater several )eeks to veriy that the !hange really is

permanent.

@a1e sure itGs wor1in lon term* not Nust once2


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DM Chec1list

DM )mplement3$ali!ate the Corrective Action

Chec1list?

• Bas an action plan %een !efine!<

• Bave responsi%ilities %een assine! to implement the

Corrective Action

• Bas timin %een esta%lishe!<

• Bas reuire! support %een i!entifie!<

• What in!icators will %e use! to verify the outcome<

•What controls are in place to assure the fix is as inten!e!<

• Do we have the riht team mem%ers to procee! to the next

step<


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Chec1 your 1nowle!e

Why is it important to $erify the CorrectiveAction< /ele!t all that apply

A+ )t isnGt

=+ "o ma1e sure the root cause was a!!resse!

C+ "o ensure no other issues were cause! %y thecorrective action

D+ "o close the form

The correct answer is B and C – The !erifcation step allows the

team to re!iew the implemented correcti!e action plan ore%ecti!eness in eliminatin' the issue andor pre!entin' it rom

escapin' to the customer. >t also lets the team decide i anynew issues were 'enerated by the selected action plan.


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Chec1 your 1nowle!e

Who shoul! complete the verification step<A+ )n!epen!ent %ut veste! participant

=+ 'rocess Owner

C+ Quality @anaer

D+ Company 'resi!ent

The correct answer is A – the !erifcation process is completed

by an independent but !ested participant* not normally part othe ori'inal correcti!e action team. &resh (yes are best.


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Chec1 your 1nowle!e

When is verification complete!<A+ )mme!iately after fix is implemente!

=+ Within 9 !ays of implementation

C+ After 6999 pieces are pro!uce!

D+ As !etermine! %y the team %ase! on volume an!criticality of !efect

The correct answer is D – !erifcation timin' ?exes dependin'

on the criticality o the deect and the time it ta,es todetermine based on product !olume i the root cause was

eliminated. @ormally a "auntity o pieces must be produced*and dependin' on how oten the part is ordered this may ta,e a

couple o shits or a couple o months.


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,teps in an 8D






• "@; )mplement3$ali!ate Corre!tive A!tion



Day

67 ( 78hrs

6 wee1s

9 !ays

D 'revent recurrence3,hare the


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??© 2013 Eaton, All Rights Reserved.

,olution /D>0

#ddressing the Systemic issues is key to /reventing -ecurrence (usuallythe +th ,hy reveals the systemic problem )ollow up. i.e. did the

implementation of the corrective action re5uire any changes to other

documents such as work instructions or control plans *s the corrective

action sustaining ,e need to share these best practice solutions! so others can learn from

our work. %ur 63 includes a “systemic action” section as part of the "# close out

process 1 this is a part of the “7olution 7haring” and “/revention”

process. ,e need to continue developing means to share best practices

Others can learn from our wor1* share the information2


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?-© 2013 Eaton, All Rights Reserved.

D Chec1list

D 'revent reoccurrence3,hare the solution

Chec1list?

• Bas the practice %een stan!ar!i4e!<• Bave all appropriate personnel %een notifie! of the chanes<

• Bave all chanes %een interate! to our existin system /wor1instructions* proce!ures* ;@A* Control 'lans etc+0<

• Bow will the practices %e share!<


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Chec1 your 1nowle!e

Which of the followin items may reuireup!ates to prevent future occurrences<

A+ mployee Roster

=+ Control Documentation /Control plans* p;@A* ;low

charts* Wor1 instructions0C+ Quality @anaer

D+ $en!or @aster

The correct answer is B – essentially all documentation that

controls the production process needs to be re!iewed orupdates to incorporate any actions that resulted rom thecorrecti!e action plan* to allow the fx to be sustainable.


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-0© 2013 Eaton, All Rights Reserved.

Chec1 your 1nowle!e

Durin the prevent recurrence step which ofthe followin items are complete!<

A+ Containment

=+ Root Cause )!entification

C+ ,harin :essons :earne!D+ 'ro%lem Definition

The correct answer is C – Durin' the pre!ent recurrence step

the team ta,es the opportunity to complete a let)to)ri'ht loo,across the portolio and share lessons learned with the

or'aniation* recordin' best practices.

,


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,teps in an 8D






• "@; )mplement3$ali!ate Corre!tive A!tion



Day

67 ( 78hrs

6 wee1s

9 !ays

8D R i th "


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8D Reconi4e the "eam

Remem%er to close out the paperwor12

8D R i th " /D>80


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8D ( Reconi4e the "eam /D>80

/ermanently eliminating problems is e'tremely satisfying in

itself

"# Team members are providing a very important service

to us all! so everyone should recogni8e the efforts of the

people participating in "orrective #ctions

The /erson -esponsible for "losure #pproval thanks and

congratulates the members of the Team

Jour team has !one a lot of har! wor1* reconi4e this2

-,tar2

, f 8D


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,ummary of 8D

8D in the automotive in!ustry has %een very effective in !rivin

improvements

Our 8D format must %e utili4e! for all Corrective Actions

,u%mitte! to Cooper 'ower ,ystems?

Quic1 Containment ( Within 78 hours2

"rue Root Cause !etermination se ffective "ools

tili4e! the 5 Why

A!!ress %oth Detection an! Occurrence

)mplement ,ystemic Corrective Actions to !rive

improvements2

8D Ch 1li t


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8D Chec1list

D8 Reconi4e the "eam

Chec1list?

N Bave we recor!e! the teams wor1 appropriately so that others facin

similar pro%lems in the future may refer to them<

N What unfinishe! =usiness remains<

N Bave in!ivi!ual team mem%ers %een informe! that it is now

complete<

Ch 1 1 l !


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-;© 2013 Eaton, All Rights Reserved.

Chec1 your 1nowle!e

Who hol!s the primary responsi%ility tocomplete the Reconi4e the "eam ,tae<

A+ Quality @anaer

=+ O'P $'

C+ 'erson responsi%le for closure approvalD+ $alue ,tream @anaer

The correct answer is C – the person responsible or closure

appro!al is the primary cheerleader or the team and expectedto ac,nowled'e the e%orts o all in!ol!ed. >n (aton* a 'ood

method or team reco'nition is the ()tar pro'ram.

Ch 1 1 l !


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Chec1 your 1nowle!e

Durin the Reconi4e the "eam step which ofthe followin items are complete!<

A+ All paperwor1 is complete!

=+ Root Cause )!entification

C+ ,harin :essons :earne!D+ 'ro%lem Definition

The correct answer is A – >n addition to reco'niin' the team

and their e%orts it is !ital that all associated documentation iscaptured and stored or uture reerence durin' this step.

,


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--© 2013 Eaton, All Rights Reserved.

,ummary

,e2ve covered

#ll steps of 63 3etailed discussion of -"# Training in + ,hy #nalysis

The 63 "orrective #ction process is necessary for continual

improvement 1 immediate need is to drive reduction in "ustomer"omplaints0

&veryone needs to use these tools 1 63 needs to become part of our

culture.

8D nee!s to %ecome part of our culture* inraine! into our DKA2

Review

3 l d th f f th li k


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3own load the form from the link

Review


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Q9/ulse will send an

automatic email notifying

you an 63 is re5uired.

Review


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Q-'ulse will sen! you remin!ers every other !ay untilyou summit your Corrective Action to your ,Q an!

your ,Q closes out the Corrective Action in the Q-

'ulse system

,ystem @aintenance


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,ystem @aintenance

@a1e sure we have the riht contacts in our system

"he Quality Contact is the person who will %e ettin the email

notification+

)f you nee! to chane a contact information you will nee! to #O to the

same Cooper ,upplier we% site an! open a Chane of Contact.

information form

Questions


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Questions

Acronyms


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Acronyms

7W6B 7 4ho, 4hen, 4here, 4hat, Ko), Ko) >any

AKO$A ( Analysis o Lariation

C',D ( Copper Po)er /ystem "ivision

DO ( "esign o E*periments

;@A ( =ailure >ode and Ee!ts Analysis

RCA ( Root Cause Analysis

,CA 7 /upplier Corre!tive A!tion


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8d corrective action root cause

Documents