8D Notes

Who TML Assembly No 14 engine plant, Bhosari.
What Millenial shaft not getting assmbled on main frame.

Where Symptom reported on customer line for parts which were manufactured at Hadapsar facility
When Symptom reported on 10.05.24 in first shift for parts which were manufactured on 08.05.202
Why OD of millenial shaft required was 35 +/- 0.1 which was observed to be 35.2 and above.
How many out of 350 shafts manufactured on 08.05.2024 52 were found to be oversize.
Problem statement:
TML reported line stoppage due to failure in

assembly of millenial shaft on main frame on
10.05.24 due to 52 out 350 shafts were found to
be oversize by 0.1 mm.
These components were maufactured at ABC

components, hadapsar on 08.05.24 in first shift.
Point of Cause:
Product Design Design

Process Design Design
Mfg Deffect Operation in which charecteristic related to problem is controlled.
manufactured at Hadapsar facility of ABC components.
were manufactured on 08.05.2024.
bserved to be 35.2 and above.
nd to be oversize.
Problem OD of millenial shaft required was 35 +/- 0.1 which was observed to be 35.2 and above.
D4: Find and Verify Root Cause
E
Escape
Why problem escaped
1 Product Design: 1
Verification of design
Validation of Design
2 Manufacturing / Process Design: 2
Initial Process Capability

PTR / SPR approval
3 Manufacturing Deffect: 3
Setup approval / First piece

inspection
Inprocess Inspection
Final Inspection
Tools used:
Brainstorming
Why - Why Analysis
1 which was observed to be 35.2 and above.
Find and Verify Root Cause
O
Occurrence
Why problem Occurred
Product Design: 1
What went wrong in product
design.
Manufacturing / Process Design: 2

What went wrong in Mfg Process
design.
Manufacturing Deffect: 3
Which event related to 6M

created the problem.
Final Inspection
Tools used:
Funnel approach
Cause and Effect Diagram
IS / IS Not analysis
Pareto
Benchmarking
On-Off Experiment
Scatter Diagram
Paired Comparision
Control Charts
Histogram
Why - Why Analysis
S
Systemic
Why QMS did not prevent the problem.
Product Design:
DFMEA
Manufacturing / Process Design:
PFMEA
Manufacturing Deffect:
PFD, PFMEA, Control Plan and WI
Tools used:
Brainstorming
Why - Why Analysis
Escape Cause
Product Design
1 Verification or validation not conducted.
Verification or validation conducted but not compatible with
2 current operation conditions.
Inputs / conditions reffered during verification and validation
3 are not relevant.
Customer abuse and other noise factors not considered while
4 designing verification and validation studies.
5 Samples / Protos not representating design specifications.

6 Test cycles under estimated considering life of vehicle.
7 Test Equipments having measurement error.
Process Design
Initial Capability study not performed.
Layout inspection not done during PTR.

Qty considered for Initial capability not
adequate.
Measuring Equipment selected is not
compatible with current operation.
Measurement system variation is significantly
high.
Manufacturing Deffect
Inspection not done.
Inspection frequency / sample size not
adequate
Measurement system variation is
significantly high.
Measuring equipment has significant error.

Systemic Cause
Product Design
Design Guidelines : Not available / not reffered / not
1 relevant / not updated.
Design Softwares : Not available / not reffered / not relevant /
2 not updated.
3 DFMEA not done.
4 DFMEA does not include this problem as failure mode.

DFMEA does not include relevant causes related to failure
5 mode.
DFMEA does not include appropriate controls related to
6 causes identified.
7 Design standards / baselines / benchmarks not available.

Process Design & Manufacturing deffect
Process Design Guidelines : Not available / not
reffered / not relevant / not updated.
PFMEA not done.

PFMEA does not include this problem as failure
mode.
PFMEA does not include relevant causes related
to failure mode.
PFMEA does not include appropriate controls
related to causes identified.
Control Plan : Not available / not reffered / not
relevant / not updated.
WI / SOP for manuacturing operation : Not

available / not reffered / not relevant / not
updated.
Occurrence Cause Why the deffect occurred.
Step
1 Brainstorming
2 Logical Screening by SME
3 Comparative Screening
4 Verification of Cause
5 Identify Root Cause
6 Verification of ARC
Tool Output
C&E diagram
Potential Causes
Paynter Chart
Probable Causes
IS ISNOT analysis Possible Causes
On-Off Experiment
Paired Comparision
Actual Causes
Box Plot
Scatter Plot
Why-Why Analysis Actionable Root causes (ARC)
On-Off Experiment Validated Actionable Root causes (ARC)

IS ISNOT ANALYSIS
20.05 15.05
Sr. No. Probable Causes IS IS NOT Difference Possible Causes
1 Operator ABC ABC No No
2 Shift B A Yes Yes
3 Cutting insert Widea Sanvik Yes Yes
4
5
Verification / Validation of Causes
1 On-Off Experiment
Conduct two trials:
a Switch on the cause and see if problem occurs If on condition pro
b Switch off the cause and see if problem occurs If on condition pro
2 Paired Comparision
Consider if Problem is attribute and causes are variable.
Take 8G and 8B Parts / vehicle.
Collect the data as per 8G and 8B.
Assign the data in asscending or descending order for cause.
Identify differenting point from top and bottom.
Capture top count, bottom count and total count.
If total count is 10 or more than cause is verified.
3 Scatter Plot
If on condition problem occurs and in off condition problem does not occur - Cause Verified.
If on condition problem occurs and in off condition also problem occur - Cause is not verified.
D5: Selection of Permanent Corrective Action.
1 Sumarise list of actionable Escape, Occurrence and Systemic Cause.

2 Escape Cause:
Branstorm and identify potential mistake proofing oppurtunities.
Perform Merit and risk analysis
Merit: Cost, Ease of Implementation, Effort required, Overal
Risk: OHS, Legal, Env, Financial risk, End user.
Select best suitable option (Ideal condition : Highest merit and lowest
Perform pilot study / simulation and verify effectiveness of selected e
If problem is not re-occuring finalise Escape PCA.
3 Systemic Cause:
Brainstorm desired actions based on systemic cause.
Strengthen Management system elements like : Guidelines, Standard
4 Occurence Cause:
Branstorm and identify potential error proofing oppurtunities.
Perform Merit and risk analysis
Merit: Cost, Ease of Implementation, Effort required, Overal
Risk: OHS, Legal, Env, Financial risk, End user.
Select best suitable option (Ideal condition : Highest merit and lowest
Perform pilot study / simulation and verify effectiveness of selected O
If problem is not re-occuring finalise Occurence PCA.
5 Sumarise PCA for EOS (Escape, Occurrence & Systemic).
ystemic Cause.
oofing oppurtunities.
n, Effort required, Overall Timeframe.

End user.
Highest merit and lowest risk)
ffectiveness of selected escape PCA.
ke : Guidelines, Standards, Softwares, DFMEA, PFMEA, Control Plans, WI, SOPs.
fing oppurtunities.
n, Effort required, Overall Timeframe.

End user.
Highest merit and lowest risk)
ffectiveness of selected Occurence PCA.
D6: Implement Permanent Corrective Action.
1 Create implementation plan and identify required resources (FTG).

2 Identify change point / breakpoint for implementation of PCA.
3 Create contingency plan / stock and backup for rolling back to previous version if
4 Train / OJT all relevant team members.
5 Conduct PTR considering PCA as changes to existing product and process.
6 Perform Re-PPAP as per customer defined submission level.
7 If problem does not re-occur in subsequent lot / batches consider PCA effective a
8 Horizontal deployment of PCA across all other relevant / similar products, proces
previous version if required.
nd process.
der PCA effective and stop all ICA initiated in step D3.
ar products, process, operations, equipments, employees, customers, suppliers.
D7: Prevent System related issues. (Change Management)
1 Update design documents like Guidelines, softwares, DFMEA's, DVP's.

2 Update Process documents like PFD, PFMEA, Control Plan, WI/SOP's.
3 Update Maintenance documents like Machine history cards, PM records, critical s
4 Update Training records like OJT, Training, Skill Matrix, Induction records etc.
M records, critical spares etc.
on records etc.

8D Notes

Uploaded by

Copyright:

Available Formats

8D Notes

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

8D Notes

Uploaded by

Copyright:

Available Formats

Who TML Assembly No 14 engine plant, Bhosari.

What Millenial shaft not getting assmbled on main frame.

TML reported line stoppage due to failure in

These components were maufactured at ABC

Product Design Design

D4: Find and Verify Root Cause

2 Manufacturing / Process Design: 2

Initial Process Capability

Setup approval / First piece

Find and Verify Root Cause

Manufacturing / Process Design: 2

Which event related to 6M

Manufacturing / Process Design:

PFD, PFMEA, Control Plan and WI

5 Samples / Protos not representating design specifications.

Layout inspection not done during PTR.

Measuring equipment has significant error.

3 DFMEA not done.

4 DFMEA does not include this problem as failure mode.

7 Design standards / baselines / benchmarks not available.

PFMEA not done.

WI / SOP for manuacturing operation : Not

2 Logical Screening by SME

5 Identify Root Cause

IS ISNOT analysis Possible Causes

Why-Why Analysis Actionable Root causes (ARC)

On-Off Experiment Validated Actionable Root causes (ARC)

1 Sumarise list of actionable Escape, Occurrence and Systemic Cause.

n, Effort required, Overall Timeframe.

ke : Guidelines, Standards, Softwares, DFMEA, PFMEA, Control Plans, WI, SOPs.

n, Effort required, Overall Timeframe.

1 Create implementation plan and identify required resources (FTG).

1 Update design documents like Guidelines, softwares, DFMEA's, DVP's.

You might also like