8D Problem Tracking and Resolution

8 D's Format
Tracking number Customer Number Open Date

Customer: Part number: Part Name:

Rev
DESCRIPTION OF DEFECT AS REPORTED:

D0 The Planning Stage:

Define overall activity and target date for completion Is an Emergency Response Action Needed?
Yes, containment and break point required Date
No, the notification does not put at risk the stoppage
of the production lines and/or leaks to the End User

D1 Establishing the Team:

Department Name Skills Responsibility
Production Supervision Process Owner
Process Engineering Process Improvements Process Instructions
Electrical Test Engineerin Electronic test Test methods
Quality Problem solving Champion

D2-A Initial Problem description:

Process Flow Diagram for the problem Sketch / Photo of the Problem
Outline process flow in sequence and highlight where problem can occur.

Start
Start /End
Cut & Strip Wires to length
Process step
Crimp Terminals onto stripped wires
Inspection
Tin stripped ends without terminals
Sequence
Poke black and white wires into connector
Decision Point
Join all wires together with a tie rap
Storage
Perform Electrical Test
Process step
w/ inspection
Perform final inspection as per Product Inspecti

Package for stock

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 8D Problem Tracking and Resolution
2B Problem Definition / Statement & Description

Y N 1 Correct Process?
Are the work instructions standardized, correct, current, and legible?
Were the instructions/procedures followed?
Has the operator been on the job 2 weeks or longer?
Is the operator trained and/or received annual refresher training?
Did the operator follow the Reaction Plans?
Was the Control Plan adequate?
Was the Control Plan followed?

2 Correct Tool?
Are tools, fixtures, gages, &/or error proofing in place & being used?
Are tools functioning correctly (i.e.: not broken, bypassed, not worn, set correctly, etc.)?
Are machines functioning correctly (i.e.: PM done, fixtures/ locators maintained, etc.)?
Was the gage(s) mastered and properly functioning?

3 Correct Parts?
Is the correct part for the application clearly identified & being used?
Is workplace org. effective (i.e.: part# marked, storage area/racks labeled…)?
Is the part storage effective(i.e. keep parts free of debris, damage, breakage)?

4 Parts in Spec?
Is the part within specification?
Is the variation within specification acceptable?
Is the variation acceptable to the customer?

5 Process Variation Acceptable?

If any of diamonds 1-4 are N (NO), 5 is “N” !

D2-C Real Problem Description:

D3 Develop Interim Corrective Actions

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 8D Problem Tracking and Resolution
D4 Identifying & Verifying Root Cause
D4-A Brainstorm the possible causes of the problem

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8D Problem Tracking and Resolution

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 8D Problem Tracking and Resolution
D4 Identifying & Verifying Root Cause
D4-B FISHBONE

MATERIALS MANPOWER METHODS

MACHINES MEASUREMENT Documentation

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 8D Problem Tracking and Resolution
D4 Identifying & Verifying Root Cause
D4-C 5 Why Analysis
Technical cause of the
problem:

Therefore
M1
Why did the Manufacturing System not

Therefore
M2
Why?
Therefore
M3
Why?
Therefore
M4
Why?
Therefore
prevent this?

M5
Why?

M-RC
Why?
Therefore Root Cause
Q1
Why did the Quality System not Protect the

Therefore
Q2
Why?

Therefore
Q3
Why?
Therefore
customer from this?

Q4
Why?
Therefore
Q5
Why?

Q-RC
Why?
Therefore Root Cause
P1
Why did the Planning System not Predict

Therefore
P2
Why?
Therefore
P3
Why?
Therefore
P4
Why?
Therefore
P5
Why?

P-RC
this?

Why?

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8D Problem Tracking and Resolution
Root Cause

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 8D Problem Tracking and Resolution
D5 Identify Permanent Corrective Actions

Action # Problem Corrective action

D6 Implementing & Validating the PCA

Status Key
Verified by Methode

Completed

Not Completed

Status
Planned Actual How was effectiveness
Action # Champion Implement date Implement date verified? Comments

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 8D Problem Tracking and Resolution
D7 Preventing Recurrence

Knowledge
Symbol Key Status Key Database
O Original location Verified by Methode

Best Practices
X Similar part/process Completed

Launch Lessons
N/A Not Applicable Not Completed

Learned
KBD
Champion
Containment
Manufacturing C/A
Detection C/A
System C/A
C/A

Management System manual

Document, System Review (as applicable)

Standardized Work instructions

Inspection Work instructions
Process Flow Charts
Design FMEA/ Process FMEA
Process Control Plan
Packaging Instructions
Gages
PPAP
Engineering Change approval
Preventive Maintenance system

D8 Recognizing Team Efforts

Was this problem solving exercise effective? Has it been verified with a follow-up?
Y N Name, Signature Title Date

8-D is a quality management tool and is a vehicle for a cross-functional team to articulate thoughts and provides scientific determination to details of problems and
provides solutions. Organizations can benefit from the 8-D approach by applying it to all areas in the company. The 8-D provides excellent guidelines allowing us to get to
the root of a problem and ways to check that the solution actually works. Rather than healing the symptom, the illness is cured, thus, the same problem is unlikely to
recur.

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 Complete and include as a Cover Sheet for each Corrective Action Response submitted.

CHECK:
CAR STEP GUIDELINES T
Yes / No / NA

Supplier Avnet
1a. D2: Problem Statement 1. Problem described by Avnet 1.
Yes Yes 1b. D2: Problem Description 1. What? 2.
2. When?
SHORT and LONG Term Responses
Sections 1 & 2 are required for both

No No
3. Where? 3.
NA NA
4. Who Reported?
5. How Many?
6. Lot Information?

Supplier AVNET
2. D3: Interim Actions 1. Clean Date? 1.
Yes Yes 2. Part/Packaging Identification?
3. Defect/Suspect quantity at Customer 2.
No No and Supplier pipeline?

NA NA
4. Certification method? 3.

Supplier AVNET
3a. D4: Root Cause Identification 1. Use of 5-Why analysis? 1.
Yes Yes

No No 2.

NA NA
3.

4.
3b. D4: Verification of Root 1. Replication / Recreation of failure where
Cause applicable?
5.
2. Use of statistical data / evidence where
applicable?
4, 5, 6 and 7 are required for Long Term Responses

Supplier AVNET D5 & D6 Permanent Specific, detection, systemic actions

4. 1. 1.
Corrective Action taken with planned / implementation
Yes Yes dates and responsibility.

No No
How did you verify specific, detection
2.
and systemic corrective actions?
NA NA
Evidence or documentation to support
the validity of corrective action.
 Sections 3, 4, 5, 6 and 7 are required for Supplier AVNET
5. D7: Preventive 1. Steps to ensure process control to 1.
prevent reoccurrence of the same
Yes Yes Sustain/Control issue?

No No

NA NA

Supplier AVNET
6. D7: Evidence 1. Documents showing evidence of 1.
changes inplemented
Yes Yes
2. Minimum requirements are PFMEA,
No No Control Plan or Work Instructions

NA NA

Supplier AVNET Evidence of similar product / process

7. D7: Read Across 1. 1.
addressed.
Yes Yes

No No

NA NA

CAR SUBMITTED BY:

Supplier Contact/ QCR Number Date Phone

CLOSURE OF CORRECTIVE ACTION:

Supplier Development / Quality Engineer visit required?

Yes No

CAR CLOSED BY:

AVNET Quality Engineer Date

VNET Supplier Development Date

AVNET
e submitted.

TIPS

Use IS/IS NOT analysis;

Is the analysis being reported on the
problem as the Customer sees it?

Use information provided in QCR.

Describe how is good product differentiated

from bad?

Estimate time/date when Customer will get

certified product for clean point?

Identify if the certification is through 100%

gauging, visual or functional check?

Is there cause-effect relation between

why's?

Cover Specific / Detection / Systemic

failures?

Specific - What caused the particular

problem to happen?

Detection - Why did the issue escape the

Supplier's process?

Systemic - Think in terms of procedures,

policies, standards, etc…, that failed to
prevent the failure of specific and detection.

Use fault samples, validation samples,

statistical data, post implementation PPM to
show evidence of implemented corrective
action.
Use of SPC, Pareto / Trend Charts, Audits,
PM Checks, Error Proofing, additional
testing.

PFMEA, Control Plan, Work Instructions,

Gage R&R, Alerts, Flow Charts, Process
Specs, etc…

Manufacturing or Design guidelines,

Lessons Learned documents, etc…

Email
 LOG CHANGE HISTORY NAA-MQ-03
Revision Date Rev. Level Reason for Change Issuer:
Issuer: