CAR Report Number:

Classification

Corrective Action Report (CAR) A B C Date Opened:

Corrective Action Type:

Customer Concern / Complaint Internal - Continual Improvement
Nonconforming Product or Service Customer Name:
Quality Maintenance / Plant Engineering
Delivery or Logistics Concern Location:
Process / ManufacturingMaterials / Delivery
Other: Report #:
Tooling / Design / Product Engineering
Example: PR&R, DMR, SMR, QN, SMRR, etc.

RMA#: Date Reported:

Health & Safety Ergonomics Environmental
CSI
Containment Required: CSII Reported By: Chemical Release Report No.:

Repeat Nonconformance Medical Aids Report No.:

Supplier Concern / Complaint Lost Time Report No.:

Nonconforming Product or Service Supplier Name: Preventive Action

Delivery or Logistics Concern Location:
Other:
Other: PCN Number:

CSI
Containment Required: CSII
Repeat Nonconformance
Audit Concern

TS-16949 Opportunity for Improvement Internal External (Insert photo or sketch here)

ISO-14001 Minor Nonconformance Associated Clause or Element Number:

HS&E Major Nonconformance Auditor(s):

Materials Repeat Nonconformance Auditee(s):
Human Resources Other: Target Closure Date:

Problem or Concern Reported:

Plant / Location: Group:

Part Number(s): Vehicle Program:

CAR Champion: Champion's Title:

Process Owner: Process Owner's Title:

A
CAR Project Location:

Date CAR Initiated: 0 Initial CAR Project Response Date:

Business Unit PPS:

CAR Project Team Members:

Establish a small group of people (5-6 maximum) with the process/product knowledge, allocate time, authority, and skill in the required disciplines to solve the concern or problem and implement corrective actions.

Name: Title:
1

External Contacts:
1. Name: Title: Company:

Tel.: Email: Fax.:

2. Name: Title: Company:

Tel.: Email: Fax.:

WGW-QUA-F-002 3/20/13 Page #1

Corrective Action Report CAR Report No.: #REF!
Interim Containment Action Plan *WGW-QUA-F-050 Action Plan may be used as an alternative tool

Interim Containment Action(s):* Owner: Date Implemented Verified By

Description of Communication Plan Owner Date Implemented

Description of Exit Criteria:

Review of PFMEA Review of Control Plan Review of Inspection Procedure Review of Error Proofing

Define and implement containment and/or short term corrective actions to isolate the effect of the concern or problem from the Customer until permanent resolution and long term actions have been
implemented. Verify the effectiveness of the containment actions. Initial response to the Customer must occur within 24 hours
Page #2
#REF!
Note: "Why Shipped?" Cause & Effect Diagram below -- scroll down

CAUSE & EFFECT DIAGRAM CAR No. #REF!

HIGHLIGHT PRINCIPLE CAUSES TO BE ADDRESSED

WHY PRODUCED/WHY DID IT OCCUR? Potential Root Cause(s) that Created Problem

MACHINE METHOD MATERIAL

PROBLEM STATEMENT (Effect)

 CAUSE & EFFECT DIAGRAM CAR No. #REF!
HIGHLIGHT PRINCIPLE CAUSES TO BE ADDRESSED

PEOPLE MEASUREMENT ENVIRONMENT

 CAUSE & EFFECT DIAGRAM CAR No. #REF!
HIGHLIGHT PRINCIPLE CAUSES TO BE ADDRESSED

WHY SHIPPED? Potential Cause(s) that Allowed the Problem to Escape

MACHINE METHOD MATERIAL

PROBLEM STATEMENT (Effect)

0
 CAUSE & EFFECT DIAGRAM CAR No. #REF!
HIGHLIGHT PRINCIPLE CAUSES TO BE ADDRESSED

PEOPLE MEASUREMENT ENVIRONMENT Page #3

#REF!
Corrective Action Report Drill Deep - 5 Why Root Cause CAR Report No.: #REF!

Problem or Concern Statement:

0

P1
Why did the planning
process not predict the Why? P2
severity correctly?
Why? P3
Why? P4
Why?

Prc: Severity Root Cause

M1
Why did the Why? M2
manufacturing process not
prevent the occurrence? Why? M3
Why? M4
Why?

Mrc: Occurrence Root Cause

Q1

Why did the Quality Why? Q2

process not detect the Why? Q3
defect to protect the
Customer? Why? Q4
Why?

Qrc: Detection Root Cause

Page #4
#REF!
Corrective Action Report Drill Deep Worksheet CAR Report No.: #REF!
Plant: 0 Group: 0

Customer: 0 Location: 0
Part No.: 0 Program: 0

Implementation of Corrective Action

5 Whys Corrective Action Owner Due Date
PREDICT THE SEVERITY
P1 0
Why did the planning process not
PREDICT the defect or concern?

P2 0

Predict P3 0

Pla nning process - P4 0

inform at iona l cont ent
in FMEAs and CPs

P-RC 0

Why did the manufacturing process M1 0

not PREVENT the defect or concern?

M2 0

Prevent M3 0

Manufacturing process -
standardized work and
error proofing M4 0

M-RC 0

Why did the quality process not

Q1 0
PROTECT the Customer?

Q2 0

Prot ect Q3 0

Qualit y process -
detect ion &
responsiveness Q4 0

Q-RC 0

K1

K2

Key findings from this 5-Why K3

analysis?

K4

K5
RC = Root
Cause

Page #5
 Action Plan For:

CAR No.: #REF!

Revision Date: Revised By:
Issue Identified 25%
Ongoing Action Plan Identified 50%
Date Reviewed: Date Reviewed: Closed Action Actions Implemented 75%
Date Reviewed: Date Reviewed: Needs attention before it becomes critical Success Confirmed 100%
Date Reviewed: Date Reviewed: Overdue/Critical

Current Condition and

Expected Outcome:

TARGET
TRACKING OR WHAT IS AFFECTED? RESPONSIBLE COMPLETION ACTUAL STATUS
Seq. # REFERENCE NUMBER (see pop up comment)
DATE ISSUED NONCONFORMANCE ACTION(S) TO BE TAKEN OWNER COMPLETION DATE COMMENTS COMPLETED (%)
DATE

2
3

4
5

10
11

12

13

14

15

16

17
18

19

20

21
22

23
24

25
#REF!
Corrective Action Closing
CAR Project Verification CAR Report No.: #REF!
Documents Updated:
PFMEA Control Plan Process Flow N/A

Procedure(s):

Work Instruction(s):

Form(s):

Other:

Error Proofing Implemented? Yes No N/A

Is Corrective Action Effective? Yes No N/A

Is Further Action Required? Yes No
Been addressed as Lessons Learned? Yes No N/A

Verified By:
Title:
Date:

Verification Steps/Comments:

CAR Project Completion Date:

Closed By:
MR / Auditor Approval (optional): Date:

CARs for External Submission

CAR sent to Customer Representative: 0

Date completed CAR sent to Customer:

CAR Delivered via:

Congratulate the TEAM Recognize the collective efforts of the team.

Page #7
#REF!
8D Response Report
Customer/Company: Woodbridge 8D No.:
Cust/Ext Assigned#: 8D Initiator:
Cust/Comp Location: Date Open:
Cust/Comp Part #: Initial Response Date:
Vehicle / Program: Target Close Date:

INTERNAL or EXTERNAL Actual Close Date:

D1 TEAM MEMBER NAMES/TITLES:
Champion:
Team Leader:
Team Members:
D2 PROBLEM STATEMENT/DESCRIPTION (quantify, one defect per 8D)

D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):

(Consider: customer site/warehouse, in transit, WFC warehouse/on line/lab/hold, etc. % Effective Date Implemented Verified By
Note how product and/or packaging will show containment activity has been completed.)

D4 DEFINE AND VERIFY ROOT CAUSE(S): % Contribution

EXPOSURE / IMPACT ANALYSIS, ARE SIMILAR PRODUCTS / PROCESSES EXPOSED TO THIS FAILURE Yes: No:
MODE OR IMPACTED BY THIS ROOT CAUSE?

IF YES, AFFECTED TEAM NOTIFIED:

D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA): % Effective

HAS ERROR PROOFING BEEN IMPLEMENTED THROUGH THESE CAs? Yes: No:

IF NO, EXPLANATION OF
ERROR PROOFING CONSIDERATION:

D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA): Target Date Actual Date

D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE: Mistake Proofing: Target Date Actual Date
How are you going to ensure it can't happen again?

HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS / PROCESSES?:

Check boxes Control Plan FMEA Process Flow Map/Proc./Work Instr./Form Preventive/Predictive Maintenance
that apply: Add to Internal Audit Calibration Tooling/Gaging Other:
Set-Up Process/Instructions
D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.

Internal Auditor's comments to validate this CAR:

Name/Sign: ______________________________________________ Date: ___________________

All initial 8D's and revisions must be sent to appropriate personnel for review prior to sending to the internal/external customer within required timing.

WGW-QUA-F-002 3/20/13

#REF!
Note: This PDCA Worksheet may be used in place of and to combine the Interim Containment Actions, Drill Deep Form and Permanent Corrective Actions together. Initiatives
(Corrective Actions) for the individual 5 Whys determined for the "P's" (Planning), "M's" (Manufacturing) and "Q's" (Quality) are to be listed on this form as they would have been in the
Drill Deep form.

PDCA Worksheet CAR #: #REF!

Status / Legend
ACTION PLAN: Plant:
R - Late
Y - Maybe Late
G - Completed
ROOT CAUSE STATEMENT: Department:
IMPROVEMENT OPPORTUNITY: Champion:
BIC INDICATOR AFFECTED: Date Revised:

PLAN DO CHECK ACTIONS

EFFECTIVE?
Schedule Task Timing Reviewed by: MEASUREMENT

Status Item Initiative Task Resp. Date Opened Target Date Close Date Who Date Base Projected Actual Yes/No

Total Measured
PDCA ITEMS Open PDCA Tasks Improvement:

Total Comp. Percent Completion Red Yellow Green Not Due

0 0 #DIV/0! 0 0 0 0

#REF!
 HS&E NON-CONFORMANCE REPORT (NCR) NCR #
# of Audit sub-
element
LOCATION: ELEMENT UNDER REVIEW: AUDIT DATE
Indicate Audit Element under review
Name of location being audited Date Audit performed
REFERENCE: Identify Applicable Plant Procedure
RISK MAJOR MINOR AUDITOR: Person performing audit of the element

o
AUDITEE: Person responsible at Plant
NON-CONFORMANCE DESCRIPTION:

Auditor to complete this section

Identify the objective evidence the auditor observed

AUDIT ELEMENT REQUIREMENT:

Auditor to complete this section

Identify what is expected

Response due to Auditor by: Date agreed to by the auditor & auditee to have decided what the corrective
action is to be.
ROOT CAUSE ANALYSIS:

To be completed by auditee. List the root causes that led to the Non-Conformance.

CORRECTIVE ACTION:

To be completed by auditee. What steps are to be taken to fix the problem.

Submission Date: Submitted By: Implementation Target Date.

When corrective action submitted to auditor Who submitted corrctive action When corrective action is to be completed
CORRECTIVE ACTION COMPLETED AND IMPLEMENTED SATISFACTORILY
Signed for Closure date comments
Comments on completness or objective evidence of
corrective action go here.
Site Manager: Signed by site manager when corrective action complete

Auditor: Signed by auditor when corrective action complete

#REF!
 Corrective Action Numbering System

CAR Numbering System Requirments - External

External Cars shall be numbered using "CAR" plus "Plant Code"-"Calendar Year"-"Sequential Report Number"
Example: CAR - TRO - 04 - 001
CAR - abbreviation for "Corrective Action Report"
TRO - Woodbridge Plant/Location Code - example "TRO" is Troy
04 - Calendar Year - example 04 is 2004
001 - Sequential Report Number
- example 001 is the first CAR issued in 2004
- 001, 002, 003…etc.
ALERT Numbering System Requirments
Note: Alert numbers shall use the CAR's location code, calendar year and sequential report number.
The Alert for the CAR example above would be numbered: TRO-04-001
CAR Numbering System Requirments - Internal
Internal CARs shall be numbered using the "Plant Code"-"Department Code"-"Calendar Year"-"Sequential Report Number"
Example: TRO-QUA-04-001
Troy - Quality department - 2004 - first CAR report for calendar year.

Woodbridge Plant/Location Codes

Plant / Location Plant Code Plant / Location Plant Code
Addison ADD Pilar PIL
Adelaide ADL Romulus RML
Atlanta ATL Sao Bernardo SBC
Auburn Hills AUB Saltillo Molded SLT
Bedford BDF Saltillo Lamination SLL
Blenheim BLN Sao Paulo SPL
Brodhead BRD Sarnia/Corunna SAR
Brampton BRP St. Peters STP
Betim BTM Tilbury Molded TLB
Cacapava CPV Tilbury Enerflex TEX
Chattanooga CHT Troy TRO
Camacari CAM Whitby WHB
Del Rio DLR Whitmore Lake WHM
El Paso ELP Woodbridge Corporate Lab CQL
Enerflex Solutions EXS Woodbridge North (Kipling) WBN
Fairless Hills FRL Kipling - Lamination KPL
Fremont FRM Kipling - Slab KPS
Grand Rapids GRA Woodbridge South (Kipling) WBS
Kansas City KNS Kipling 093 KP3
Kansas City Sequencing KCS Kipling 095 KP5
Leon LEO Kipling 096 KP6
Melbourne MLB
Manchester MNC
Morval/Kitchener MRV
Mississauga MSS
Mexico City MXC

Department or Function Codes

Assembly & Sequencing ASQ Management MGT
Corporate Lab CQL Marketing MKT
Corporate R&D CRD Materials MTL
Data Management DAT Office Services OSV
Design Engineering DES PECT PCT
Development Matrix DVM Process PRO
Engineering ENG Product Development PDV
Finance FIN Production PRD
Human Resources HRS Purchasing PUR
Health, Safety and Environmental HSE Purchasing Engineering PEN
Information Technology ITS Quality QUA
Plant Lab LAB Sales/ Account Administration SAL
Legal LGL Technical Services Group TSG
Logistics LOG Tooling TLG
Maintenance MNT

#REF!