8D

USER GUIDELINE

November 2007
 Supplier convention goal

8D is one of tools in R&N to define improvement

activity for non-compliance POE parts, and it makes
smooth communication between R&N and suppliers

Good 8D report with evidences can increase reliability

of suppliers to customer

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• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
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 Summary
• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
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 8D method presentation 8D
• The principle of 8D method is PDCA：
• ：
» Nonconformity explanation
» Prompt customer protection
» Root cause analysis
» Recurrence preventive and permanent action plan
» Efficiency validation
» Standard update

• The 8D file is composed of：

• ：
» 8D format from GQE in Nov.2007

» 8D related documents : Support documents required to provide evidence

8D is helpful document for supplier to make action plan and implement

improvement activity smoothly

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 8D method presentation
• WHO ?
. R&N all suppliers。

• SCOPE ?
All concerns of supplier responsibility

• WHEN?
- Received nonconformity from GQE, or claim from R&N

• HOW?
To use all of the tools to solve problems

• WHY?
• - To meet PSW requirements, and to protect customers and prevent
recurrence in short and long term

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 8D
• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
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 8D overall process

t0 t0 + t0 + t0 +
48Hours max 10Days max 30Days max
From receiving
claim form R&N
S S S

R R R

1 2 3 4 5 6 7 8
Follow up
Concern Similar Part Temporary Final Perma- Action
Initial Analysis action
Details Conside- (of non Imediate analysis nent confirmati
Standardiz
ration detection) Action Action on
ation

P D C A

Supplier Responsibility : Communicate 8D & enclose evidence

S

R RENAULT SQA / Logistics Department Responsibility : validation of the

efficiency of the action plans (questions or if needed 8D audit)

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 8D
• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
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 8D template extract of GQE

Step 6
Step 4 : Temp :Permanent
Step 1 : What is CMR ?
CMR
the non
application
conformity ?

Step 7 :
Step 2 ： Same Effectiveness
problems for validation
similar parts第二
步：

Step 5 :
Step 3 : WHY? Step 8 :
WHERE, Standardization
WHEN, WHY ?
第

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 8D
• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
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 STEP 0: Team building

To solve problems and implement

countermeasures, need to small group who
has knowledge of process and product,
authority and technology

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 STEP 1: Concern Details

➢ Purpose :
– To describe problems based on R&N non-conformity
description standards
–
– To estimate customer effects
– To describe non-conformity can cause detailed effects

– To check if recurrence or not

➢ Recommended tools :
WWWWWHH,…..
The more precise the description is ,
The faster you can react ,
The better you can find root causes .

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 W W W W W H H tool example

• Who is concerned ?:

• What happened ?:

• Where does it occur ?:

• When did it happen ?:

• How does it occur / How was it detected ?：

•

• Why is it important / customer effect ?:

•

• How many ? : P / 14
 STEP 1: Concern Details

Example N°1 Find the wrong example?

? ????ssssssssssssssssssssssssssssssssssssssss
ssssssssssssssssssssssssssssssssssssssssssss
? ssssssssssssssssssssssssssssssssssssssssssss
ssssssssssssssssssssssssssssssssssssssssssss
ssssssssssssssssssssssssssssssssssssssssssss
? sssssssssssssssssssssssssss

Example N°2

Parts manuf actured on assembly line

n°2B50 on W5

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 STEP 1: Example
Bad sample

Best sample
 STEP 1: Concern Details : KEY POINTS

• Write based on in-detail and facts (5W2H)

•

• Do not mix individual opinion and fact !!

• ！

• Add Picture / Sketch / Figure

•

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 STEP 2: Similar parts consideration

➢ Purpose : To prevent non-conformity is spread to other plant and parts

– Find all parts to effect other customers potentially

– The supplier has the responsibility to inform all R&N plants of non-
conformity who have effects.

➢ Recommended points to be checked :

• Part list related to non-conforming parts
• Detection place analysis
• Parts list, possible to give effects in the same process

• Potential risk part list, possible to effect other parts or customers

➢ Required tools :
WWWWWHH（5W 2H）,…..

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 STEP 2 : Example

Find the wrong example ?

Example N°1

Example N°2

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 STEP 3: Initial Analysis

➢ Aim目的 : Identify non-detection causes

– Find where the non-conformity should have been detected

– Find why the non-conformity was not detected

-- Evaluate process control (Mistake or omission)

• Find deviation with standards

• Find root cause of outflow

➢ Required quality tools :

5W 2H, 5Why, Ishikawa, process flow chart, control process.

Need to set up
Required documents: audit, control countermeasures for all
! process, analysis… reason of outflow

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 STEP 3 : Example

Find the wrong example ?

Example N°1

5W?

Example N°2

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 STEP 4: Temporary Countermeasure – Immediate

➢ Purpose : To prepare action plan to protect the customer within 24Hours.

- To prepare correct action plan to prevent non-conformity. Not only sorting
non-conforming products

- To define inventory in supplier and customer, and on transportation, it should

be No. of non-conforming parts, not percentage

- To provide how to isolate non-conforming parts in R&N plant

-

➢ Recommended point to be checked :

Skilled sorting worker, process update (Check sheet etc)

➢ Required Tools :
WWWWWHH,…..

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 STEP 4: Example
Example N°1 Find the wrong example ?

Example N°2

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 STEP 4: Example
Best sample

1) Sorting Method for suspected parts and Vehicle

After checking gap between cable and column yoke, if gap was less than 5 mm or interference happened,
cable tie to fix the cable to gear housing was reworked.
。

2) Sorting activity in customer plant & Logistic warehouse of supplier – Apr 23~26
Division Checked Quantity NG Note

Product for customer 336 -

C-EPS check
in Logistic Warehouse 1EA : interference
Product for CKD 421 2
1EA : GAP 5mm↓

Vehicle check
Customer plant 1,800 5 5EA : GAP 5mm↓
in renault plant

TOTAL 2,557 7 They were reworked

 8D processus
t0 t0 +
48Hours max
From receiving
claim form R&N
S

1 2 3 4 5 6 7 8
Concern
Initial
Details Similar Part Temporary
Analysis
Conside- (of non Imediate
ration Action
detection)

P D
SUPPLIER requested actions :
S - Prepare 8D with evidences to ensure all actions implemented are appropriate

- Inform SQF of estimated completion date

! R
RENAULT SQA / Logistics Dept. will assess and validate (if needed by 8D -audit) :
- To evaluate supplier action was appropriate
- To keep deadline

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 STEP 5 : Final analysis
➢ Aim ：To define the root cause for manufacturing and outflow

-- All group members analyze the root causes within given time (Not only
quality people but all related people should attend)
– Analysis with facts.
Histogram

。 Correlation diagram Cause-effect Diagram


 

 
 
 Pareto Diagram

➢ Recommended tools : Curbs

100%
WWWWWHH, Ishikawa, 5W….
5W

Requested document: analysis

! tool, diagram, ….

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 STEP 5 : Example

Material Mean Medium

Defective product arrived from tier 2 supplier Inappropriate manufacturing mean Inappropriate lighting
Product damaged after control Alternate mode on manufacturing mean Too noisy
Reliability defect - could not be seen at 0 km No start-up check of pokayoke Inappropriate manufacturing conditions
Defect only when manipulating / dynamic testing Bypassed pokayoke (key on pokayoke) Crisis on this item
Disturbance due to rework on close parts How to answer? Overflow
Undetected drift of a caracteristic If your company has no analysis standards (FTA, Crisis on other item with impact
Product is conformant, but specification too low Ishikawa, 5 why, etc...) use this proposed on issue
standard. Unrespected FIFO
Add more causes if needed… AddIfmore
your company
causeshasif one, use the one currently
needed… Logistics issue
used in your company and insert it here.

Operator medically unable Occurence

Work instruction unclear Untrained operator
Time allowed for operation is not adapted Unauthorized worker
Work instruction not respected Skill matrix out of date
Operator could not access work instruction Operator did not respect work instruction
Current procedure is inappropriate/does not exist Operator did personal move See causes of non-detection
Procedure not respected Operator sick when at workstation
Most recent audit shows a non conformity Poor communication (teamleader->worker)
Log sheet not available at workstation Start-up checklist not filled in Defect generated by control
Defect is close to pause
Social issue during production
Methods Manpower Measurement

5 WHY analysis (must be conducted on the more likely causes)

Potential Cause Check Why Check Why Check Why Check Why Check Why Action Who Date

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STEP 5 : Example
Best sample

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 STEP 6 : Permanent countermeasure

➢ Aim : Establish an action plan in order to remove non-conformity and non-

detection root causes.

- To define permanent action plan to prevent recurrence

- To validate the appropriate of action plan

➢ Important points to be checked :

4M change, Standards update, Control plan modification, Training …

➢ Recommended tools :
scheduled, decision matrix……

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 STEP 6 : Example
Best sample
Date
No Cause Process Action Plan R&R
appearance
Cause of

To prevent that cable tie is assembled in wrong May-29

1 Not Robust Fixture position, fixture was improved. [Done H.B. Kwon
]
Cable Tie
Assembly
in Supplier
No process Added inspection for cable tie position after Apr-29
2 to check assembly at Supplier to detect if cable tie is [Done H.B. Kwon
Cable Tie Position assembled in wrong position ]
Cause of not detection

Incoming Added Caleb Tie position during Incoming

No process Apr-29
Inspection Inspection at Mando to detect if cable tie is
3 to check [Done J.H. Lee
in MANDO assembled in wrong position
Cable Tie Position ]

May-08
Vision 1. Vision inspection was implemented [Done
No process
Camera using white pixels ]
to check
4 Inspection J.H. Jung
Cable Layout
in MANDO 2. Wire layout is directly inspected additionally Jun-07
[Done
]
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 8D processus
t0 +
t0 t0 +
48Hours max
10Days max
From receiving
claim form R&N S S

R R

1 2 3 4 5 6 7 8
Concern Similar Part
Temporary Final Perma-
Details Conside- Initial Analysis
ration (of non Imediate analysis nent
detection) Action Action

P D
SUPPLIER requested actions :
- Prepare 8D with evidences to ensure all actions implemented are appropriate
S

RENAULT SQA / Logistics Dept. will assess and validate (if needed by 8D-audit) 雷 :
R
! - To evaluate supplier action was appropriate
- To keep deadline

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 STEP 7 : Countermeasure confirmation

➢ Aim : Check and prove the permanent action plan efficiency

- To validate the process is well managed by the Permanent

countermeasures

➢ Key points :
Poka Yoke efficiency(Fool proof).

➢ Recommended tools 推荐工具 :

Poka Yoke, audit, TPM….

Need to check the compliance of sampling frequency, inspectors’ skill level etc

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 STEP 7 : Example

Example N°1 Find the wrong example ?

Example N°2

NO!!

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 STEP 7 : Example
Best sample
1. Checked for improved cable tie assembly fixture and inspection at Supplier : May-29

- Method : Process on-site audit

- Auditor : ??? (Supplier Quality Assurance Team)
- Evidence for corrective action

Improved Fixture Visual Inspection and Marking Measurement Result

Cable tie assembling jig

Guide bar
Clamp

It was confirmed that It was checked that measurement

After cable tie position inspection
it’s possible to prevent wrong result for actual cable tie
witness marking was checked
position assembly of cable tie assembly position
 STEP 7 : Example
Best sample
2. Incoming Inspection result was monitored by ERP system : Jun-27

Method : Recorded history check for Cable Tie position check at ERP system

(In case of NG parts, parts are rejected and isolated)

- Auditor : ??? (Quality Control Team)

 STEP 7 : KEY POINTS

Quality wall activity for customer protection in

R&N and supplier plant should be done
continuously till Step 7

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 STEP 8 : Follow up action / standardization

➢ Purpose : Standardization, Horizontal deployment

- Set up permanent countermeasure to prevent similar

nonconformity

-Update relevant standards

➢ Key points :
Capitalization, Procedure and standards update, relevant
standards update

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STEP 8 : Example

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 8D process

t0 t0 + t0 + t0 +
48Hours max 10Days max 30Days max
From receiving
claim form R&N S S S

R R R

1 2 3 4 5 6 7 8
Follow up
Concern Similar Part Temporary Final Perma- Action
Initial Analysis action
Details Conside- (of non Imediate analysis nent confirmati
Standardiz
ration detection) Action Action on
ation

P D C A

!
RENAULT SQA / Logistics Dept. will assess and validate (if needed by 8D -audit) :
R - To evaluate supplier action was appropriate
- To keep deadline

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 8D
• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
P / 40
 8D supplier guide file

Enclosed the file :

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 CONCLUSION
• 8D is a tool to not only support communication between R&N and
suppliers but solve problems
•

• And R&N can evaluate the appropriateness of the suppliers’

countermeasures through 8D application
•

Ensure permanently customer protection

Relevant document update and execution is the best way for

permanent customer protection

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 CONCLUSION

R&N PQA requests prompt

reactivity to solve problems and
prevent recurrence.

And, will support suppliers’ activity

if necessary

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 8D
• 8D method
•

• 8D overall process
•

• 8D template
•

• 8D step by step
•

• 8D Supplier Guide File

•

• Appendix : 8D example
•
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EXAMPLE (Quality non conformity)

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