Instructions and Guidelines for Tenneco 8D Problem Solving WorkbookP06_23_7_2B.xls
Tab Color CodingRequired Element
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.
Optional - but strongly Recommended
If any optional tab tool is not utilized: 1) Remove the tab 2) The information is expected to reside within the 8D tab
At minimum one of such tabs must be used
Delete RC identification tab 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).
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).
Instructions and Guidelines for Tenneco 8D Problem Solving Workbook
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.
If any optional tab tool is not utilized: 1) Remove the tab 2) The information is expected to reside within the 8D tab
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8 - DISCIPLINE REPORTTraceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
Photo(s) /Sketch/Print Section:(1A) Team Contact
Team Lead:Phone:Dept/Activity:
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/PNTEN System/PN:
Customer System/PN:
(1D) Concern Initiator Name:Phone:Dept/Activity:
(2) PROBLEM DESCRIPTION (all Background Symptom details): In this section please explain in a series of statements or bullets: Who Found - What was found - How was it found- Where was it found - When was it found:How Many/Frequency/ any Pattern: - Prior History or Background:- Anything else to understand the issue for proper containment and to understand root cause:
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 REPORTTraceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
(3) EMERGENCY RESPONSE and CONTAINMENT ACTIONS DATE VERIFICATION
Assignee TARGET COMPLETE
(4) ROOT CAUSES Y/N Is / Is not Diagram Attached: Y/N 5 Why's Diagram (REQUIRED)
CAUSE(S) FOR OCCURRENCE: Method of Root Cause Verification
ACTION(S): Include emergency actions (For Product related - All existing material and material to be produced must have containment actions until issue PCA is verified )
METHODS (Documented WI and ID Markings)
Fishbone Diagram Attached:
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8 - DISCIPLINE REPORTTraceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
CAUSE(S) FOR ESCAPE:
(5) CORRECTIVE ACTIONS (6) VERIFICATIONDATE
INTERIM CORRECTIVE ACTIONS: RESPONSIBILITY TARGET COMPLETED METHODS
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8 - DISCIPLINE REPORTTraceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
RESPONSIBILITY TARGET COMPLETED METHODS
(7) PREVENTION (6) VERIFICATIONDATE
PERMANENT CORRECTIVE ACTIONS: Must address all verified Occurrence and Escape factors
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):
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8 - DISCIPLINE REPORTTraceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
RESPONSIBILITY TARGET Complete METHODS
(8A) TEAM MEMBERS
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):
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8 - DISCIPLINE REPORTTraceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
Local Reviews (Always Required) Signatures mean approval Corporate Reviews (Mandatory for Corp. Issues)
Operations Management
Quality Representative
Quality Management
(8B) Reviews and Approvals - Names-Titles-Dates
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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
Insert Issue Description
Specific/Occurrence
Why
Why
Detection Why
Why Why
Why Why
Systemic Why Root Cause
Why Why
Why Why
Why Root Cause
Why
Why
Root Cause
Read Across Actions Timing Lessons Learned Summary
Insert Issue Description from above again
Insert Last box of Root Cause Occurrence
Tips: Insert photos where needed to show conditions describing, Additional legs may be required if independent factors identified. (refer to example)
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
Therefore
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8D Document Audit 8D #__________________
Yes NoD1 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
D2 Describe the Issue2.1
2.2 Does the problem statement avoid predicting cause (Spec vs Condition) ?
2.3
D3 Containment Activities3.1 Was responsibility for containment assigned to the process owner ?
3.2
3.3
3.4
D44.1
4.2
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 Actions5.1 Was corrective action selection based on data showing a link to the issue?
5.2
Is the leader from the appropriate functional area, or is the primary functional area represented ?
Does the problem statement tell what, who, where, when, why, how many and how often?
If applicable does the problem statement include Customer and TEN part number ?
Is containment activity defined (formally documented) WI for methods and marking of material, (including dates and status) ?
Are results documented including number of inspections/number of non conformances found ?
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
Did team utilize root cause analysis tools (5 Why, Fishbone) to determine root cause?
Was ‘5 Why’ done correctly? Does it branch where necessary, does each ‘Why’ derive directly from the previous ‘Why’?
Is there a documented implementation plan (including responsibility, timeline, and completion date)?
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8D Document Audit 8D #__________________
Yes No5.3 Have all root cause factors (occurrence and escape) identified been accounted
for in the actions?
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8D Document Audit 8D #__________________
Yes NoD6 Verification of Corrective Action
6.1
D7 Prevent Recurrence
7.1
7.2
7.3
D8 Congratulate the Team
AUDIT COMPLETED BY
Auditor__________________ Date: ___________________
Auditor__________________ Date: ___________________
Auditor__________________ Date: ___________________
Comments/Feedback section
Is there documented verification that corrective actions were effective (trend charts, test results, process capability, etc.) including date of verification?
Were actions taken to prevent recurrence including updating of process documentation? (Standard Work, Product/Process Specs, FMEA, Control Plan, etc.)
Were similar internal products and processes investigated and corrections implemented to prevent failures? (has it been institutionalized)
Was applicability for external lessons learn read across out side the site been addressed?
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N/A
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N/A
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N/A
FISHBONE (ROOT CAUSE FACTORS)
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LIST ALL POSSIBILITIES IDENTIFIED THROUGH BRAINSTORMING OR WHATEVER MECHANISM TO GENERATE POTENTIALSDenote factors with (O) - Occurrence (E) -Escape or do separate fishbone for each
Man Machine (Tooling) Environment
Method (Process) Material Measurement
ü ? cross-outTrue (VERIFIED) Cause Possible Cause RULED OUT - Not a Cause
Test DirectCause:
INSERT FAILURE MODE
"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…)
Insert as many sections to the table as is needed:
Filtering Problem Description Symptom Background information:
Filtering Fishbone/Brainstorming FactorsTake each topic and put it in "C"
If a given "C" fits the criteria of every A and B Mark it on the Fishbone asa leading potential cause.
If a given "C" doesn't fits one criteria of "any " A or B CROSS IT OUT/"Strikethrough" on the Fishbone
??? - Brainstorming or Fishbone Element Potential?
PLEASE FIND A STEP-BY-STEP GUIDE TO USE THE X/Y DIAGRAMStep 1 Fill-out the process name and the date when the YX diagram was compiled
Process:Date:
1 2 3 4 5 6 7 8 9 10
Input Variables (Xs) Ranking123456789
10
YX Diagram
laminating17/12/2004
Out
put V
aria
bles
(Y
s)
Step 2 Identify the outputs of the process. In case of the 8D, this output could be the failure identified in the NCR/MRR and different potential other failures. Remark, one should avoid to redo the entire PFMEA in order to loose track of the issue on hand. Second, the team should agree on the severity of the output identified. Rating goes from 10 to 1 where 10 is the highest severity One should use the severity table defined in the AIAG PFMEA manual (latest version), table to identify severity.
Process:Date:
1 2 3 4 5 6 7 8 9 10
fore
ign
mat
eria
l
smea
rs
thic
knes
s
unbo
nded
are
a
brok
en
7 6 4 9 10Input Variables (Xs) Ranking
123456789
10
YX Diagram
laminating17/12/2004
Out
put V
aria
bles
(Y
s)
2.1 Identify output
2.2 Identify severity
Step 3 Identify the inputs of the process : what can cause any of the outputs identified. Second, the team needs to classify these root causes according the Ishikawa split.
Process:Date:
1 2 3 4 5 6 7 8 9 10
fore
ign
mat
eria
l
smea
rs
thic
knes
s
unbo
nded
are
a
brok
en
7 6 4 9 10Input Variables (Xs) Ranking
1 pressure 5 02 temperature 5 03 time 5 04 clean room practices 1 05 clean room cleanliness 1 06 washer 2 07 material properties 4 08 robot handling 2 09 human handling 3 0
10
YX Diagram
laminating17/12/2004
Out
put V
aria
bles
(Y
s)
Step 4 The team needs to agree on the likelihood that a particular root cause identified (as X) will lead to one or more issues identified (as Y). Rating goes from 10 to 1 where 10 is the highest likelihood.
Process:Date:
1 2 3 4 5 6 7 8 9 10
fore
ign
mat
eria
l
smea
rs
thic
knes
s
unbo
nded
are
a
brok
en
7 6 4 9 10Input Variables (Xs) Ranking
1 pressure 5 8 10 9 2122 temperature 5 8 10 7 1923 time 5 8 10 4 1624 clean room practices 1 5 7 775 clean room cleanliness 1 7 3 676 washer 2 10 8 1187 material properties 4 7 5 6 7 1668 robot handling 2 2 4 8 1189 human handling 3 3 4 3 4 112
10
YX Diagram
laminating17/12/2004
Out
put V
aria
bles
(Y
s)
3.2 Classify root cause Insert code : 1 = Environment 2 = Machine 3 = Manpower 4 = Material 5 = Method
3.1 Identify root cause
Step 5 In order to get an overview of the results, one has to hit the button “VIEW SUMMARY & CHARTS”
VIEW SUMMARY& CHARTS
You will have a Pareto Analysis of the root causes and a Ishikawa diagram. Other Buttons
CLEAR SHEET
Will clear all the content
DEMO Will give you a demo. Mind that to see the results from the demo,
one still needs to hit the “VIEW SUMMARY & CHARTS”
GO TO GUIDE
Return to YX Diagram
Return to YX 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 replace this tab with your action matrix.
If your issue also has an action matrix please replace this tab with your action matrix.
For Product related Issues - Cleaning the Pipeline:
Location Fall out Qty
In transit
Finished Goods
Final Assembly
Sub Assembly
Supplier Transit
Supplier Stock
Suspect Qty (by PN) (Skid, Trailers, Lot codes and Quantities)
Certification Method(Refer to document or detail here)
Certified Product Identification Method
(Pic and alerts are best)
Customer Locations
Component stock
Outside Processing
Rework Locations
Service Inventory
8D - Document Update Checklist
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Document (ID) Numbers Assignee (owner) Explanation if required
PPAP
Process Flow
PFMEA
Control Plan
Work Instructions
Standardized Work
Travelers/Routers
DFMEA
Standards or Masters
PROCESS change Approvals
Other
Potential Documents Requiring updates
(Note list may not be all inclusive)
Not Req'd(Place "X" in
box)
If Req'd Completion
Date
Training Completion
Date
In Process Checksheets and Inspection forms
Prints/Specifications/Test Methods…
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