Instructions and Guidelines for Tenneco 8D Problem Solving Workbook

P06_23_7_2B.
xls

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.

Tab Color Coding

Required Element
If any optional tab tool is not utilized: 1) Remove the tab 2) The information is
Optional - but strongly
Recommended
expected to reside
At minimum one of within the 8D tab
Delete RC identification
such tabs must be tab tool(s) not used
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).
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).
 8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #

(1A) Team Contact (2) PROBLEM DESCRIPTION (all Background Symptom details): Photo(s) /Sketch/Print Section:
In this section please explain in a series of statements or bullets:
Team Lead: Who Found - What was found - How was it found- Where was it found - When was it
Phone: found:
Dept/Activity: How Many/Frequency/ any Pattern: - Prior History or Background:- Anything else
to understand the issue for proper containment and to understand root cause :
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/PN
TEN System/PN:

Customer System/PN:

(1D) Concern Initiator

Name:
Phone:
Dept/Activity:

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 REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #

(3) EMERGENCY RESPONSE and CONTAINMENT ACTIONS DATE VERIFICATION

ACTION(S): Include emergency actions (For Product related - All existing material and material METHODS
to be produced must have containment actions until issue PCA is verified ) Assignee TARGET COMPLETE (Documented WI and ID Markings) RESULTS

(4) ROOT CAUSES Fishbone Diagram Attached: Y/N Is / Is not Diagram Attached: Y/N 5 Why's Diagram (REQUIRED)

CAUSE(S) FOR OCCURRENCE: Method of Root Cause Verification

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 8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #

CAUSE(S) FOR ESCAPE:

(5) CORRECTIVE ACTIONS (6) VERIFICATION

DATE

INTERIM CORRECTIVE ACTIONS: RESPONSIBILITY TARGET COMPLETED METHODS RESULTS

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 8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #

PERMANENT CORRECTIVE ACTIONS:

Must address all verified Occurrence and Escape factors RESPONSIBILITY TARGET COMPLETED METHODS RESULTS

(7) PREVENTION (6) VERIFICATION

DATE

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 8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #
RESPONSIBILITY TARGET Complete METHODS RESULTS

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):

(8A) TEAM MEMBERS

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 8 - DISCIPLINE REPORT
Traceabilty & Cross Reference Information
Customer # Supplier #
TEN (8D)# TEN Concern #

(8B) Reviews and Approvals - Names-Titles-Dates

Local Reviews (Always Required) Signatures mean approval Corporate Reviews (Mandatory for Corp. Issues)

Operations Management

Quality Representative

Quality Management

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 Tenneco 3-Legged 5 Why Analysis
Concern number: Date of issue: Site/Location:
Part / Process:
Permanent Corrective ActionsTiming

Insert Issue Therefor

e
Description

Specific/Occurrence Therefor
e

Why Therefor
e

Insert Issue Therefor

Why Therefor
Description from e e
above again
Detection Therefor
Why Therefor
e e

Why Therefor
Why Therefor
e e

Insert Last box of Therefor

Why Therefor
Why
Root Cause e e
Occurrence
Systemic Therefor
Why Therefor
Root Cause
e e

Why Therefor
Why Therefor
e e

Why Therefor
Why
e

Why Therefor
Root Cause
e

Why Therefor
e

Why
Tips: Insert photos where needed
to show conditions describing,
Additional legs may be required if
independent factors identified.
(refer to example)
Root Cause
Read Across Actions Timing Lessons Learned Summary
 8D Document Audit 8D #__________________

Yes No N/A
D1 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
Is the leader from the appropriate functional area, or is the
primary functional area represented ?

D2 Describe the Issue

2.1
Does the problem statement tell what, who, where, when, why,
how many and how often?

2.2
Does the problem statement avoid predicting cause (Spec vs
Condition) ?

2.3
If applicable does the problem statement include Customer and
TEN part number ?

D3 Containment Activities
3.1
Was responsibility for containment assigned to the process
owner ?

3.2
Is containment activity defined (formally documented) WI for
methods and marking of material, (including dates and status) ?

3.3
Are results documented including number of
inspections/number of non conformances found ?

3.4
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

D4 Escape
4.1
Did team utilize root cause analysis tools (5 Why, Fishbone) to
determine root cause?

4.2
Was ‘5 Why’ done correctly? Does it branch where necessary,
does each ‘Why’ derive directly from the previous ‘Why’?
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 Actions
5.1
Was corrective action selection based on data showing a link to
the issue?

5.2
Is there a documented implementation plan (including
responsibility, timeline, and completion date)?

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8D Document Audit 8D #__________________

Yes No N/A
5.3
Have all root cause factors (occurrence and escape) identified
been accounted for in the actions?

Page 12 of 22
 8D Document Audit 8D #__________________

Yes No N/A
D6 Verification of Corrective Action
Is there documented verification that corrective actions were
6.1 effective (trend charts, test results, process capability, etc.)
including date of verification?

D7 Prevent Recurrence
Were actions taken to prevent recurrence including updating of
7.1 process documentation? (Standard Work, Product/Process
Specs, FMEA, Control Plan, etc.)

Were similar internal products and processes investigated and

7.2 corrections implemented to prevent failures? (has it been
institutionalized)

7.3
Was applicability for external lessons learn read across out side
the site been addressed?

D8 Congratulate the Team

AUDIT COMPLETED BY
Auditor__________________ Date: ___________________

Auditor__________________ Date: ___________________

Auditor__________________ Date: ___________________

Comments/Feedback section

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Page 14 of 22
 FISHBONE (ROOT CAUSE FACTORS)

LIST ALL POSSIBILITIES IDENTIFIED THROUGH BRAINSTORMING OR WHATEVER MECHANISM TO GENERATE POTENTIALS
Denote factors with (O) - Occurrence (E) -Escape or do separate fishbone for each

Man Machine (Tooling) Environment

INSERT
FAILURE
MODE

Method (Process) Material Measurement

Test Direct ü ? cross-out

Cause: True (VERIFIED) Cause Possible Cause RULED OUT - Not a Cause

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 "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…)

??? - Brainstorming or
Fishbone
Element Potential?

Insert as many sections to the table as is needed:

Filtering Problem Description Symptom Background information:
Filtering Fishbone/Brainstorming Factors
Take each topic and put it in "C"

If a given "C" fits the criteria of every A and B Mark it on the Fishbone as
a leading potential cause.

If a given "C" doesn't fits one criteria of "any " A or B CROSS IT OUT/
"Strikethrough" on the Fishbone
PLEASE FIND A STEP-BY-STEP GUIDE TO USE THE X/Y DIAGRAM
Step 1 Step 3 Step 5
Fill-out the process name and the date when the YX diagram was compiled
Identify the inputs of the process : what can cause any of the outputs identified. In order to get an overview of the results, one has to hit the button “VIEW SUMMARY
YX Diagram & CHARTS”
GO
GO TO
TO GUIDE
GUIDE
Process: laminating Second, the team needs to classify these root causes according the Ishikawa split.
Date: 17/12/2004 YX Diagram
Return
Return to
to YX
YX Diagram
Diagram
1 2 3 4 5 6 7 8 9 10 Process: laminating VIEW SUMMARY
Date: 17/12/2004 & CHARTS

Output Variables
1 2 3 4 5 6 7 8 9 10

3.1 Identify root cause You will have a Pareto Analysis of the root causes and a Ishikawa diagram.

foreign material

unbonded area
Output Variables
(Ys)

thickness
Input Variables (Xs)

smears
Ranking

broken
1 Other Buttons

(Ys)
2 7 6 4 9 10
3
Input Variables (Xs) Ranking
4
1 pressure 5 0
5
6 2 temperature 5 0 CLEAR
7 3
4
time
clean room practices
5
1 3.2 Classify root cause
0
0
SHEET
8
9 5 clean room cleanliness 1 0 Will clear all the content
6 washer 2 0
10
7 material properties 4 Insert code : 0
8 robot handling 2 1 = Environment 0
3
Step 2 9 human handling
2 = Machine 0
10
3 = Manpower DEMO
4 = Material Will give you a demo. Mind that to see the results from the demo,
Identify the outputs of the process. 5 = Method
In case of the 8D, this output could be the failure identified in the NCR/MRR and different Step 4 one still needs to hit the “VIEW SUMMARY & CHARTS”
potential other failures.
Remark, one should avoid to redo the entire PFMEA in order to loose track of the issue on hand. The team needs to agree on the likelihood that a particular root cause identified (as X) will lead to
Second, the team should agree on the severity of the output identified. Rating goes from 10 to 1 one or more issues identified (as Y). Rating goes from 10 to 1 where 10 is the highest likelihood.
Return
Return to
to YX
YX Diagram
Diagram
where 10 is the highest severity
One should use the severity table defined in the AIAG PFMEA manual (latest version), table to YX Diagram
identify severity.
Process: laminating
Date: 17/12/2004

1 2 3 4 5 6 7 8 9 10
YX Diagram
Process: laminating

foreign material

unbonded area
Output Variables
Date: 17/12/2004

thickness
smears

broken
1 2 3 4 5 6 7 8 9 10

(Ys)
7 6 4 9 10
2.1 Identify output
foreign material

unbonded area

Input Variables (Xs)

Output Variables

Ranking
1 pressure 5 8 10 9 212
thickness
smears

2 temperature 5 8 10 7 192
broken

2.2 Identify severity 3 time 5 8 10 4 162

(Ys)

7 6 4 9 10 4 clean room practices 1 5 7 77

Input Variables (Xs) 5 clean room cleanliness 1 7 3 67
Ranking
6 washer 2 10 8 118
1
7 material properties 4 7 5 6 7 166
2
8 robot handling 2 2 4 8 118
3
9 human handling 3 3 4 3 4 112
4
5 10
6
7
8
9
10
 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.
 ix please
matrix.
 For Product related Issues - Cleaning the Pipeline:
Suspect Qty (by PN) Certification Method Certified Product
(Skid, Trailers, Lot codes and (Refer to document or Identification Method
Location Quantities) detail here) Fall out Qty (Pic and alerts are best)

Customer
Locations

In transit

Finished
Goods

Final
Assembly

Sub
Assembly

Component
stock

Supplier
Transit

Supplier
Stock

Outside
Processing

Rework
Locations

Service
Inventory
 8D - Document Update Checklist

Potential Documents
Not Req'd If Req'd Training
Requiring updates Document (ID)
Assignee (owner) (Place "X" Completion Completion Explanation if required
(Note list may not be all Numbers
in box) Date Date
inclusive)

PPAP

Process Flow

PFMEA

Control Plan

Work Instructions

Standardized Work

Travelers/Routers

In Process Checksheets
and Inspection forms

DFMEA

Standards or Masters

Prints/Specifications/Test
Methods…

PROCESS change
Approvals

Other

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