G8D REPORT

Title: Date Opened: Last Updated:

Product/Process Information: Organisation Information:

DØ Symptom(s):

Define and quantify the symptom. Identify customer and affected parties.

DØ Emergency Response Action(s): % Effective: Date Implemented:

Select an emergency response with or without service action only if necessary.

Verification / Validation:
Is the customer protected?

D1 Team: Name Dept Phone D2 Problem Statement:

Champion: The champion removes road-blocks.
State sympton as an object and a defect. Use repeated Whys.
Team Leader: The team leader gives assignments and reports out.
Team Members:
D2 Problem Description:

Perform 'IS' vs 'IS NOT' analysis.

Complete Cause & Effect diagram.

D3 Interim Containment Action(s): % Effective: Date Implemented:

Select an interim containment with or without service action if necessary.

Verification / Validation:
Is the customer protected?

D4 Root Cause(s) and Escape Point(s): % Contribution:

Develop potential root cause list. Can causes be verified (make problem come and go)?
Finalize root cause list. Identify control point capable of detecting the problem.

Verification:
Does the final root cause account for all known 'IS' and 'IS NOT' ?

D5 Chosen Permanent Corrective Action(s): % Effective:

Select a permanent containment with or without service action if necessary.

Verification:
What evidence do you have that this will resolve the problem at the root-cause level?

D6 Implemented Permanent Corrective Action(s): Date Implemented:

Develop an action plan for implementation. Discontinue the interim containment action.

Validation:
Confirm with customer, using symptom measurables, that the problem has been eliminated.

D7 Prevent Actions: Date Implemented:

Review problem history. Identify what allowed problem to occur and escape.

D7 Systemic Prevent Recommendations: Responsibility:

Identify system or procedures responsible for problem. Have all required changes been documented?

D8 Team and Individual Recognition: Date Closed: Reported by:

Document lessons learned and recognize teams collective effort. Celebrate task completion.

Rev 2002Aug05

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 Problem Solving Worksheet Step 1 of 4

Problem Statement
Problem Logically could be but Get
Description IS IS NOT Information

Object What object has the defect?

What objects that are similar in shape, composition,
Vehicle(s) form or function could have the defect but do not?
Part Number(s)
WH AT

Defect
Mechanism of Failure
Noise Factors
Piece-to-Piece What other similar defect(s) could have been
What is the defect?
Change over Time observed but were not?
Customer Usage Cycle
External Environment
Neighboring System(s)

On Vehicle or Where on the object is the defect observed?

Where else on the object could the defect have
Object been observed but was not?
WHE RE

First Observed Where geographically and in the process was the

Where geographically and in the process could the
defective object have first been observed but was
& Seen Since defective object first observed?
not?

When in time was the defective object first When in time could the defective object have first
observed? been observed but was not?
First Observed When in the process was the defective object first When in the process could the defective object
& Seen Since observed?
When in the life cycle of the defective object was
have first been observed but was not?
When in the defective object's life could the defect
the defect first observed? have first been observed but was not?
WH EN

Pattern Since What patterns of occurrence of the defect have

been observed with respect to time?
What patterns of occurrence could have been
observed with respect to time but were not?
In Process
Operating Cycle When during use of the defective object is the When during use of the defective object could the
Life Cycle defect observed? defect have been observed and was not?

How many objects have the defect? What is the

How many objects could have the defect but do
magnitude of the defect in terms of percentages,
Magnitude rates, patterns, trends, yield, physical dimensions,
not? What magnitude could the defect have, but
does not?
etc.? R/1000 and % in service.
HOW BIG

Defects per How many defects are there per defective object?
How many defects could there have been per
Object defective object but were not ?

Trend What is the trend (increasing, decreasing, cyclical, What could the trend have been but was not
Hazard Plot(s) etc.)? (increasing, decreasing, cyclical, etc.)?
 Problem Solving Worksheet Step 2 of 4

Comparative Analysis

Differences Changes Date

Object
Vehicle(s)
Part Number(s)
WH AT

Defect
Mechanism of Failure
Noise Factors
Piece-to-Piece
Change over Time
Customer Usage Cycle
External Environment
Neighboring System(s)

On Vehicle or
Object
WHE RE

First Observed
& Seen Since

First Observed
& Seen Since
WH EN

Pattern Since
In Process
Operating Cycle
Life Cycle

Magnitude
HOW BIG

Defects per
Object

Trend
Hazard Plot(s)
Problem Solving Worksheet Step 3 of 4

Possible Cause Hypotheses

g
 Problem Solving Worksheet Step 4 of 4

Test of Root Cause Hypotheses

a b c d e f g

Object
Vehicle(s)
Part Number(s)
WH AT

Defect
Mechanism of Failure
Noise Factors
Piece-to-Piece
Change over Time
Customer Usage Cycle
External Environment
Neighboring System(s)

On Vehicle or
Object
WHE RE

First Observed
& Seen Since

First Observed
& Seen Since
WH EN

Pattern Since
In Process
Operating Cycle
Life Cycle

Magnitude
HOW BIG

Defects per
Object

Trend
Hazard Plot(s)
 Problem Solving Worksheet

Problem Statement Comparative Analysis Possible Cause Hypotheses Test of Root Cause Hypotheses
Problem Logically could be but Get
Description IS IS NOT Information Differences Changes Date a b c d e f g

Object
Vehicle(s)
Part Number(s)
WH AT

Defect
Mechanism of Failure
Noise Factors
Piece-to-Piece
Change over Time
Customer Usage Cycle
External Environment
Neighboring System(s)

On Vehicle or
Object
WHE RE

First Observed
& Seen Since
d

First Observed
& Seen Since
WH EN

Pattern Since
In Process
Operating Cycle
Life Cycle
f

Magnitude

g
HOW BIG

Defects per
Object
h

Trend
Hazard Plot(s)

i
 D5 Decision Making

Decision Making Worksheet

End Result: Choices Available

Criteria

GIVENS: (Mandatory, Measurable, Realistic) Givens Information Y/N Givens Information Y/N

a) a) a)

b) b) b)

c) c) c)

d) d) d)

e) e) e)

How
How Good How Good
WANTS: (Objective or Subjective) Important Wants Information (0-10)
Score Wants Information (0-10)
Score
(1-10)

a) a) a)

b) b) b)

c) c) c)

d) d) d)

e) e) e)

f) f) f)

g) g) g)

h) h) h)

i) i) i)

j) j) j)

Relative Merit Relative Merit

Total Score Total Score

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 D5 _ Risk Analysis

Risk Analysis

"If we do this what may happen contrary to our interests ?"

Sources Attractive Choice

(Choice)
P S
1. RISK What characteristics of this choice may fail to
satisfy the GIVENS totally ?

2. RISK What features or characteristics of this

CHOICE compromise or threaten an important WANT ?

3. UNIVERSAL Do you anticipate problems with

the choice in any of the folowing areas ?

People
Organisation
External Influences
Facilities
Equipment
Ideas - Policies - Processes
Materials
Money - Economics
Capacity
Quality
Timing
Personal Interferences

Procedure: Investigate one choice at a time. All threat

assessment by the same individual or group.

"SERIOUSNESS" No. 10 means rejection if a probability is P = Probability (1 - 10)

certain (10 x 10). S = Seriousness (1 - 10)

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 D6 Planning Corrective Actions

Problem Prevention Worksheet

Objective of the Plan

(Include Due Date)

Priority Cues Who?

Date or
Key Steps P S P x S Possible Barriers Preventions Protection Event

Use your experience to identify steps of your Determine which Identify possible barriers How can you keep each What is your contingency plan if a problem still develops
plan that are complex, have tight deadlines, step(s) most need to completing the key barrier or cause of ? Identify the person or position responsible to begin the
are high impact, are new, etc. your attention / steps. Consider the trouble from happening protection action. Also identify the cue which tells that
resources. areas of people, or developing. What can person to initiate the protection action(s).
methods, materials, be done to protect your
machines, measurement plan's objective ?
and environmental
issues.

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