8D Corrective Action & Root Cause Analysis: © 2013 Eaton, All Rights Reserved
8D Corrective Action & Root Cause Analysis: © 2013 Eaton, All Rights Reserved
8D Corrective Action & Root Cause Analysis: © 2013 Eaton, All Rights Reserved
Preventive Action – The action that is taken to eliminate conditions that could
produce a nonconformity.
Root Cause – At its simplest form, you can turn off and on the problem in a
controlled environment. The root cause should explain 100% of the unwanted
problem/defect and that there are no additional reasons that the problem exists.
This training session will not cover Preventive actions as defined above, but
the concept of Preventing recurrence is a key part of the Corrective Action
process.
Ford’s Team Oriented Problem Solving (TOPS) systems was the precursor to
8D
1.0 Team Contact/General Information: (If inform ation is not applicable, please indicate by w riting N/A or crossing out.)
Team Members :
Checklist:
What type of problem is it?
Can we list any resources and documents which might better quantify
this problem?
Is there any evidence this problem has surfaced before?
What is the extent of the problem
Has the problem been increasing, decreasing or remaining constant?
Do we have physical evidence of the problem in hand?
Have failed parts been analyzed in detail?
Is there an action plan to collect additional data if needed?
Do we have the right team members to proceed to the next step?
The correct answer is C – Who found the defect, What was the
defect, When was the defect detected, Where was the defect
found/located, How was the defect found, and How Many units
were defective? Why is not part of the equation in Step 1:
Defining the problem. Why comes in during the root cause
analysis stage.
Ask: How did the problem occur? Ask: How was it missed?
Why? …. Why? ….
Why? …. Why? ….
Why? …. Why? ….
Why? …. Why? ….
Why = the true root cause (typically) Why = what controls need to be in place to
prevent another escape
Work through the problem, use your team and don’t skip steps!
Acronyms:
CPSD – Cooper Power Systems Division SCA – Supplier Corrective Action
DOE – Design of Experiments ANOVA – Analysis of Variance
RCA – Root Cause Analysis
You will know it is the Root Cause if you can turn the problem off and on
These are NOT root causes, they may be a contributing cause but not the
true root cause!
5 Why
Solution: Delay turning on the spot lights until one hour after
sunset, by which time midge population is down 90%. By doing
this, the food chain is broken and less frequent washings are
required.
© 2013 Eaton, All Rights Reserved. 49
Back to the calibration example using the
5 Why
5 WHYS? Analysis
5 Whys? Analysis consists of team members identifying a possible root cause by asking “Why?” until the root cause is
uncovered. It may take more or less than five Whys? To get to the Root Cause: Five is typical in most cases.
Let’s consider the gage calibration nonconformance illustrated on the CA and Root Cause tab:
Why? Gage Tech did not calibrate the gage before the due date.
Why? Calibration interval was not entered on the gage master record
Why? a.) Gage Tech didn’t know the interval when the gage was entered in
the master list
b.) Gage Tech didn’t follow up to enter the interval later.
Why? GageTrak does not force entry of the interval when entering gages in
the master list
Now that a possible Root Cause has been identified, generate a solution, implement it and check for proof that it’s effective.
Possibly some of the “facts” are not true – confirm with data.
The Corrective Action has to address the Root Cause, so it’s important
that a follow up audit verifies that the Root Cause was eliminated!
Someone with a vested interest who was not part of the Corrective
Action team is chosen by the Quality Manager to follow up.
Checklist:
• Has an action plan been defined?
• Have responsibilities been assigned to implement the
Corrective Action
• Has timing been established?
• Has required support been identified?
• What indicators will be used to verify the outcome?
• What controls are in place to assure the fix is as intended?
• Do we have the right team members to proceed to the next
step?
Checklist:
Checklist:
The Quality Contact is the person who will be getting the email notification.