Tracking Number: Customer/ Machine: Response Due Date:

COINDU251016 - 0003 Incoming Inspection 30-09-2016

Status

8D Problem Solving Worksheet – Long Form

Step 0 1 2 3 4 5 6 7 8
Action Prepare Team Describe Contain Diagnose Solve Validate Prevent Wrap

Registered problem and Long Term Corrective Long Term Corrective Long Term Corrective
Short Term Corrective Action developed but not Action implemented. Action confirmed effective.
Action in place in house. implemented. Monitoring/evaluating Problem closed.
effectiveness.
Prepare for Problem Solving - Is an Emergency Response Action Needed?
Does the problem warrant/require an 8D? If (If needed document actions in Action Item Table)
0 so comment why and proceed.

Assemble Team –
Establish a small group of people with the process/product knowledge, allocated time, authority and skill in
1 the required technical disciplines to solve the problem and implement corrective actions.

Name (Team Leader First) List the name of the participant during the analysis & add the position in the
organization
Name Position in the Organization
Antonio Carpinteyro Quality Manager Mexico
Omar Cortés Quality Engineer
Faurecia team

Describe Problem Picture of the Problem

People in the station of lamination do not
2A remove properly the plastic of the hacoflex,
as result, the leather do not paste
correctly.
Part Number(s)/ Process: Basis Milano
Customer(s)/ Machine:

COINDU Mexico

2B IS IS NOT
Incoming inspection in quality wall of Mastrotto Mastrotto facilities
Who

Part with plastic between leather and hacoflex Wrong parameters of lamination, excess of hair
or another process condition
What

the piece of leather is not stick properly Is not another condition in the piece and
process
Why

COINDU Internal Process Mastrotto Mexico

Where

Thursday, September 6th 2016 Is no other date

When

6 parts The complete shipment

How
Much/
Many
Is the second-time report previous sorting All number parts
How activities
Often
Problem Description –
People in the station of lamination do not remove the plastic of the hacoflex, as a result, the
2C leather do not paste correctly

3 Interim Containment Actions –

 Deploy a quality alert in station of lamination process (DONE)

Train all people involve in lamination process (quality alert and in the removal of the plastic) (DONE)

Train people in stations of final control in detection (DONE)

Certify all material that we have in our facilities (DONE)

Diagnose Root Cause –

Analyze for “Root Cause” of the problem. Identify and verify the Escape Point.
4A

Cause and Effect Diagram

How made/operated? Why did it get out/ fail?

People Materials/Info Machine Problem (effect) People Materials/Info Machine

The lamination of
the parts was not
done correctly

Method Environment Measurement Method Environment Measurement

Note on Diagram(s) circle the most likely contributors (3 max) from each side.
 4B 5 – Why Analysis
Ask – Why did this happen? The lamination of the parts was not done correctly

Ask – Why did this happen? The part was separated at the moment of manipulation

Ask – Why did this happen? People did not remove transparent plastic.

Ask – Why did this happen?

Ask – Why did this happen?

FINAL ROUT CAUSE: People did not remove transparent plastic

5 Identify Solutions
– Perform a work instruction in order to define correct steps to carry out the tasks in lamination
process, to remove properly the plastic (DONE)
 Request to supplier the possibility to change the color of the plastic in the hacoflex, in order to assure
that the operator remove the transparent plastic.
-

Validation –
1. Perform audits of standardized work periodically (weekly)
6 2. Perform product audits to validate this condition
3. Notify COINDU when we do not have hacoflex with transparent plastic

Prevention & Address Similar Systems

1. Evaluate people involved in the process and ensure that they follow all steps defined in work
instruction
7 2. Accord with the supplier a different color of the plastic in the hacoflex (blue)

7B Review the following documents / systems.

Completion Date
Check if
Document Assignee
Applicable
Planned Actual

Control Plans

Engineering Master Specifications

PFMEA

Manufacturing Set-up Sheet

Manufacturing Check Sheet(s)

QA Inspection Work Instructions

QA Inspection Forms

Updated WI in
WI Procedure(s) 19/10/16 Done
lamination process

Job Descriptions(s)
Inform when we could
have all hacoflex with
Job Certifications/ Recertify Open Open
different color of the
plastic
Congratulate Your Team!
- Use all forms of employee recognition and document as necessary.
8 Celebrate successful conclusion of the problem solving effort.
Formally disengage the team and return to normal duties.
Was the Problem Solving Worksheet Effective?

Yes/No Signature/Title Date