8d problem solving

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WHO IS EFFECTED BY THE PROBLEM? Date Open: 8D No.: Company: Initial Response: Address: Target Close Date: Location: Revision Date(s): Part No./Code 8D Initiator: Product Name: 8D Initiator's Spvr: Actual Close Date: D1 TEAM MEMBER NAMES/TITLES: D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D) Champion: Team Leader: Team Members: D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA): HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA? D4 DEFINE AND VERIFY ROOT CAUSE(S): % Contribution: HOW DID YOU VERIFY THE ROOT CAUSE(S)? D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA): % Effective: HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?: D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA): HOW WILL YOU VALIDATE THE PCA? HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?: Check boxes that apply: WGCPF-001 page 1 of 9 Rev. 5 18-Nov-03 THE WOODBRIDGE GROUP - 8D Response Report Customer Complaint No.: % Effective : Target Date: Actual Date: Target Date: Actual Date: D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE: Mistake Proofing: How are you going to ensure it can't happen again? Target Date: Actual Date: D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team. Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location. If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, Ontario INTERNAL EXTERNAL Control Pla FMEA Flowchart Proc./Work Instr Add to Internal Aud

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PROBLEM solving

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Blank 8D FormTHE WOODBRIDGE GROUP - 8D Response ReportWHO IS EFFECTED BY THE PROBLEM?Date Open:8D No.:Company:Initial Response:Customer Complaint No.:THESE ARE MASTER DOCUMENTS, PLEASE MAKE COPIES BEFORE TYPING ON THEM.Address:Target Close Date:Location:Revision Date(s):Part No./Code8D Initiator:Product Name:8D Initiator's Spvr:Actual Close Date:D1 TEAM MEMBER NAMES/TITLES:D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)Champion:Team Leader:Team Members:D3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):% Effective:Target Date:Actual Date:HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?D4 DEFINE AND VERIFY ROOT CAUSE(S):% Contribution:HOW DID YOU VERIFY THE ROOT CAUSE(S)?D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):% Effective:HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):Target Date:Actual Date:HOW WILL YOU VALIDATE THE PCA?D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE: Mistake Proofing: How are you going to ensure it can't happen again?Target Date:Actual Date:HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:Check boxes that apply:D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location. If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, OntarioWGCPF-001 page 1 of 9Rev. 518-Nov-03

INTERNAL orEXTERNALControl PlanFMEAFlowchartProc./Work Instr.Add to Internal Audit

InstructionsInstructionsTHE WOODBRIDGE GROUP - 8D Response ReportWHO IS EFFECTED BY THE PROBLEM?Date Open:8D No.:Move your cursor over the cells with red triangles for additional instructions. Always check the tabs at the bottom of the worksheets for more information. Contact the originator for errors or suggestions for improvement or questions: Karen Watts, Sr. Mgr. Corp. Quality & CI (248) 280-6583Company:Initial Response:Customer Complaint No.:Address:Target Close Date:Location:Revision Date(s):Part No./Code8D Initiator:Product Name:8D Initiator's Spvr:Actual Close Date:D1 TEAM MEMBER NAMES/TITLES:D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)Champion:What are the symptoms that the customer is seeing? Specify the internal/external customer problems by identifying in quantifiable terms who, what, when, where, why, how, how many (5W2H) of the problem.Team Leader:Team Members:LINK TO PROBLEM SOLVING WORKSHEET - PROBLEM DESCRIPTIOND3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):% Effective:Target Date:Actual Date:Define and implement containment actions to isolate the problem from any internal/external customer until permanent corrective action is available. Verify the effectiveness of the action. The ICA is a type of 'Band-Aid' used to protect the customer until the root cause is determined and the permanent correction can be implemented.How effective is your ICA so the customer does not see the problem?LINK TO DECISION MAKING WORKSHEET & RISK ANALYSISHOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?How can you make the problem come and go - prove it - test results - document it.D4 DEFINE AND VERIFY ROOT CAUSE(S):% Contribution:Identify all potential causes (due to a change) which could explain why the problem occurred. Isolate and verify the Root Cause by testing each potential cause against the problem description and test data (does it explain the IS,IS/NOT'S in D2?). Identify alternative corrective actions to eliminate root cause.What % of the problem is caused by the root cause(s) (must have 100% total)LINK TO PROBLEM SOLVING WORKSHEET - ROOT CAUSE WITH THEORY TESTINGHOW DID YOU VERIFY THE ROOT CAUSE(S)?How can you make the problem come and go - prove it - test results - document it.D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):% Effective:Through pre-production test programs, quantitatively confirm that the selected corrective actions will resolve the problems for the customer and will not cause undesirable side effects. Define contingency action, if necessary based on the risk assessments. This step describes WHAT you will do.How effective is your PCA so the problem is cured not masked? (must have 100% total)LINK TO DECISION MAKING WORKSHEET & RISK ANALYSISHOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:How can you make the problem come and go - prove it - test results - document it.D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):Target Date:Actual Date:Define and implement the best permanent corrective actions. Include the removal of the ICA. Choose on-going controls to ensure the root cause is eliminated. Once in production, monitor and evaluate the long-term effects and implement contingency actions, if necessary. This step describes HOW you will do it.LINK TO PLANING AND PROBLEM PREVENTION WORKSHEETHOW WILL YOU VALIDATE THE PCA?Use validation tools for long term results: Trend - Pareto - Paynter, etc.D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE: Mistake Proofing: How are you going to ensure it can't happen again?Target Date:Actual Date:Modify the management systems, operating systems, practices and procedures to prevent recurrence of this and all similar problems. (What is the "Escape Root Cause"? What in your system allowed this problem or any problem from leaving your plant and not getting detected?). Choose on-going controls, including mistake proofing methodology, such as the use of process or design features to prevent manufacture of nonconforming product/service. Review control plans, FMEA's, flowcharts, etc. for revisions.Note: Develop Action Plan (can use worksheets to help brainstorm)HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:Check boxes that apply:D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location. If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, OntarioWGCPF-001 page 2 of 9Rev. 518-Nov-03

INTERNAL orEXTERNALControl PlanFMEAFlowchartProc./Work Instr.Kwatts:PURPOSE: is to provide a method to document corrective actions taken for problems, concerns, or system improvements.

SCOPE: All Woodbridge departments may use this form to document a concern that relates to an internal or external problem, system improvements, procedural gap that occurs between departments and high TPPM. The document can be used when the root cause is known or unknown. When the following criteria is met, the entire 8D methodologies using the links in this spreadsheet should be used: 1. Problem with Cause Unknown2. Need to Cure not Mask the Problem3. Need a Team-Approach to Solving the ProblemIf the Root Cause is known, verify it with data, testing, experiments, etc. Can you make the problem come and go? If so, then just use the 8D form as a means of documenting what you did and attach the data to prove you found the Root Cause and verified it.One 8D form is to be used per defect or concern, but may be used for multiple part numbers with same defect & root cause.

RESPONSIBILITY: The initiator is responsible to manage and track the progress of the 8D request and response. The supervisor/department manager is responsible to review the progress of the 8D for closure. 8D's related to quality systems will be reviewed by the site MR and will be discussed at Management Review meetings. 8D's related to TPPM levels that exceed Woodbridge or customer standards will be initiated by the Plant and will be available for review by Corporate Quality and/or discussion with the customer.

A problem-solving training class is highly recommended and is available through the Woodbridge Group. Contact Karen Watts at (248) 280-6583 for more information.KWatts:Check the appropriate box for internal (your site) or external (customer related) problem.KWatts:8D number is assigned by the person that is responsible for maintaining 8D's.KWatts:This is to reference the customer notice number in which this report is responding.kwatts:Establish a small group of people, when needed, with the process and/or product knowledge, allocated time, authority, and skill in the required technical disciplines to solve the problem and implement corrective actions. If using a team, the group must have a designated champion and team leader. If the project is being completed by one person, the supervisor would be the Champion and the person doing the 8D would be the leader.Add to Internal AuditLINK TO PROBLEM SOLVING WORKSHEET - PROBLEM DESCRIPTIONLINK TO DECISION MAKING WORKSHEET & RISK ANALYSISLINK TO PROBLEM SOLVING WORKSHEET - ROOT CAUSE WITH THEORY TESTINGLINK TO DECISION MAKING WORKSHEET & RISK ANALYSISLINK TO PLANING AND PROBLEM PREVENTION WORKSHEET

EXAMPLETHE WOODBRIDGE GROUP - 8D Response ReportWHO IS EFFECTED BY THE PROBLEM?Date Open:5/25/038D No.:BR-03-001Company:Example CustomerInitial Response:5/26/03Address:1234 Somewhere St.Target Close Date:6/10/03Location:Mytowne, MIRevision Date(s):5/30/03, 6/5/03Part No./Code260038D Initiator:Joe SmithProduct Name:Front Seat Back CushionSupervisor:Al BossmanActual Close Date:6/9/03D1 TEAM MEMBER NAMES/TITLES:D2 PROBLEM STATEMENT/DESCRIPTION (quantify) (one defect per 8D)Champion:Al BossmanFront Seat Back Cushions 26003 have voids. June returns from Example Customer exceeded 450 TPPM. Of the 31 pieces returned, 26 pieces were rejected for voids (84% of returns). TPPM calculation = 31 rejections/35,000 pieces shipped x 1,000,000 = 886 TPPMTeam Leader:Joe SmithTeam Members:Les Shippet, Stan Tistics, Ima GoodguyD3 CHOOSE AND VERIFY INTERIM CONTAINMENT ACTION(S) (ICA):% Effective:Target Date:Actual Date:Review all material in-house and at Example Customer. Post "Alert" in plant and communicate defect to all management personnel. 100% inspection area set up in cell 1 for each shift. Management audit in warehouse and hand initial each label.100%26-May-0326-May-03HOW DID YOU VERIFY THE EFFECTIVENESS OF THE ICA?Paynter Chart Attribute p-chart (0 found) by management audit.D4 DEFINE AND VERIFY ROOT CAUSE(S):% Contribution:1. Foam splashing on seal. 2. Malfunctioning auto vent: Cleaned after demold, proper air pressure and cycling is occurring but still malfunctioning by clogging.1. 70% 2. 30%HOW DID YOU VERIFY THE ROOT CAUSE(S)?Can make voids come and go by altering pour pattern without splash and with splash. New auto vents produce no clogs thus no voids.D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION(S) (PCA):% Effective:1. Change robot pour pattern 2. Change auto vent.100%HOW DID YOU VERIFY THE EFFECTIVENESS OF THE PCA?:Monitored 30 pours for splash and checked auto vent after 30th pour for no clogs.D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTION(S) (PCA):Target Date:Actual Date:1. Moved pour head 10 mm from the parting line (was 35 mm) and start in front and end in back. 2. Replaced auto vent with new one.30-May-0329-May-03HOW WILL YOU VALIDATE THE PCA?Paynter chart 100% on-line inspection first 3 shipments. Attribute study from management dock audits on first 3 shipments to Example Customer (np-chart 10 pieces every hour at end of line).D7 SYSTEM PREVENTION ACTIONS TO PREVENT RECURRENCE: Mistake Proofing: How are you going to ensure it can't happen again?Target Date:Actual Date:Add pour pattern to FMEA. Statistically monitor cycles/pours to determine when auto vents should be changed (prior to clog). Add auto vent check to PM program and revised work instruction BRPMW-01805-Jun-0305-Jun-03HAS CORRECTIVE ACTION/IMPLEMENTATION BEEN REVIEWED AGAINST DOCUMENTS?:Check boxes that apply:D8 TEAM AND INDIVIDUAL RECOGNITION: Recognize the collective efforts of the team.Original: To the dept. Sprv/Mgr. Copy: All initial 8D's and revisions must be sent to appropriate personnel at the location. If this is a WFC customer related 8D, copy to the Corporate Quality Management Department in Mississauga, OntarioWGCPF-001 page 3 of 9Rev. 518-Nov-03

INTERNAL orEXTERNALControl PlanFMEAFlowchartProc./Work Instr.Add to Internal Audit

Problem Description D20PROBLEM DESCRIPTION (D2)Move cursor over each cell for questions to help you with the description.1. Operational Definition What's wrong with what? Why?(Type in D2 here)Return to 8D Form Instructions2. Description of ProblemISIS NOTGET INFO ONWHAT ObjectDefectWHERE Seen on objectSeen geographicallyWHEN First seenWhen else seenWhen seen in process (life cycle)HOW BIG How many objects have the defect?How many defects per object?What is the trend?Updated By:Update Date:Update #:WGCPF-001 page 4 of 9Rev. 518-Nov-03

kwatts:The operational definition (problem statement) is a simple descripion of what the customer sees. It includes an object and a defect. Example: cargo panels have bubbles, frame has broken welds, rear seat back has voids.KWatts:Every "IS" must have at least one "IS NOT".Kwatts:The update information on this line is to record when this form was updated and by whom.Return to 8D Form Instructions

Problem Solving Worksheet D4Move cursor over cells with the red triangle for more information. Questions for each column>>>>>>>The 8D #, Operational Definiation, IS and IS NOT data will transfer from the Problem Description Worksheet. If it does not, re-record the information and "IS & IS NOT" description.What is Different, Unique, Special or True when you compare the IS to the IS NOT?What has Changed in, on around or about the dfference and when did it occur?Record the date of when the change occurred in this column.How could this change have created the problem? List a theory for each CHANGE and then create any other ones by brainstormingReturn to 8D Form Instructions0PROBLEM SOLVING WORKSHEET (D4)1. Operational Definition What's wrong with what? Why?(Type in D2 here)(Type in D2 here)2. Description of ProblemISIS NOT3. Deductions About Facts and Other Information4. Possible Causes3a. Differences3b. ChangesDateList Change-How TheoriesWHAT Object00ADefect00BWHERE Seen on object00CSeen geographically00DWHEN First seen00EWhen else seen00FWhen seen in process (life cycle)00GHOW BIG How many objects have the defect?005. Test causes for probability (+, -, ?) Page 2 Does it explain Is/Is Not fact?How many defects per object?006. Steps to verify Root Cause? (make the problem come and go)What is the trend?00Updated By:Update Date:Update #:WGCPF-001 page 5 of 9Rev. 518-Nov-03

kwatts:What you write in this column must be NEW information not already written on this sheet and must be only TRUE of the IS.kwatts:Keep in mind that the "When" section does not have a divider line between the "differences" and the "changes". A "difference" is automatically a "change" in the "When" section because it is dealing with time.kwatts:Look at the changes that you wrote and brainstorm to come up with at least one theory for each "change" as to how that "change" could cause the problem. Make sure you include "HOW" that change could cause the problem.kwatts:How can you make the problem come and go? Remove the cause from the process and then put it back into the process again. Record it here.Kwatts:The update information on this line is to record when this form was updated and by whom.Return to 8D Form Instructions

Testing Possible Causes D4InstructionsThe theories should transfer over from the previous page. If they don't, retype the theories in.For each theory (potential root cause), ask "If the ______theory is the cause of my problem, does it explain, in and of itself, why the "IS" is affected, but never the "IS NOT"?Record: "+" (plus) for Yes: Both "IS" and "IS NOT" are explainedRecord: "-" (minus) for No: Does not explain "IS" and/or "IS NOT"Record: "?" (question mark) for need additional information to draw conclusion0TESTING POSSIBLE CAUSES (D4 Continued)Change-How Theories0000000Return to 8D Instructions"IS's"ABCDEFG1234567891011121314151617Comments/ Follow-Up ItemsUpdated By:Update Date:Update #:WGCPF-001 page 6 of 9Rev. 518-Nov-03

Decision Making Worksheet0DECISION MAKING WORKSHEET (D3 & D5)move cursor over cells with red triangles for more information(1) END RESULT:Return to 8D Form Instructions(2) CRITERIA:(4) CHOICES AVAILABLE - (INNOVATE)ABCDGIVENS: (mandatory, measurable, realistic)(5) INFOY/N(5) INFOY/N(5) INFOY/N(5) INFOY/NWANTS: flexible limits, subjective, realistic(3) How Important (1-10)INFO(5) How Good (0-10)ScoreINFO(5) How Good (0-10)ScoreINFO(5) How Good (0-10)ScoreINFO(5) How Good (0-10)Score0000000000000000000000000000000000000000Relative MERIT (total score)000000Updated By:Update Date:Update Rev #:WGCPF-001 page 7 of 9Rev. 518-Nov-03

kwatts:Record the 8D number here.kwatts:Make a brief statement that describes the desired end result. It defines the scope of the decision to be made, and provides a focus for the team.kwatts:The End Result is what you are trying to achieve. It should contain an action verb and a statement. It should precisely reflect the desired goal and not restrict or increase the scope of the decision.

Example: Determine the best interim corrective action.kwatts:Using the End Result statement as a focus, list all the criteria that needs to be satisfied throughout this decision.You will need to consider budget, timing , company procedures, legislation and all other criteria that the decision will need to satisfy.kwatts:Brainstorm what the possible choices or options might be to satisfy the End Result. List the titles of those options across this section in place of A,B,C and D.kwatts:List the titles for the options that you have to choose from across this row.kwatts:GIVENS are the minimum criteria that a possible choice must satisfy. If a possible choice does not meet the requirements of the GIVENS, it cannot be chosen as a final choice.GIVENS are mandatory and must be measurable.kwatts:Record information about each option that will help you to determine if the option will meet the GIVEN criteria.

Record a Y (Yes) if the option satisfies the criteria. Record a N (No) if the option does not satisfy the criteria.

Complete the GIVENS first before going on to the WANTS.kwatts:WANTS are those criteria that are desirable but not mandatory, and have some flexibility in the degree to which they are satisfied.kwatts:Decide on the relative importance of the WANT criteria.

Determine which one is considered the most important and give it a rating of 10. Then compare all the other WANTS to the most important WANT and give them a value that reflects their relative importance, in relation to the 10. It's best not to have any two numbers the same.kwatts:If an Option failed the GIVEN criteria above with an "N", you do not need to continue with more information in the WANT section. That choice has been eliminated!

For those options that passed the GIVENS with a "Y", record information about each option as it relates to the WANTS.kwatts:Looking at each WANT, assess how each of the possible choices meet that WANT. Assign a "10" in the 'HOW GOOD' column to the possible choice that best meets that WANT. Assign the other possible choices a value relative to the 'best' on 'HOW GOOD' scale of 0 - 10 (0 does not meet WANT criteria).kwatts:(This should be automatically calculated).

Multiply the value assigned to each WANT by its corresponding 'HOW GOOD' value.kwatts:This is the total of the How Important numbers.kwatts:This is the total points for each option.kwatts:This is the total of the How Important numbers x 10. The option that comes closest to this number is your number one choice.kwatts:This line is used to record when this form was updated and by whom when it is being used for problem solving.Return to 8D Form Instructions

Risk Analysis0DECISION MAKING WORKSHEET - RISK ANALYSIS (D3 & D5)move cursor over cells with red triangles for more information(6) RISK ANALYSIS: State your risks in "IFTHEN" terms."If we do this, what might happen, contrary to our interest?"Investigate one choice at a time1st ChoicePS2nd ChoicePS3rd ChoicePSReturn to 8D Form Instructions1. RISKWhat characteristics of this choice may fail to satisfy the GIVENS?2. RISKWhat features or characteristics of this choice compromise or threaten an important WANT?3. UNIVERSALUse the checklist to stimulate ideas.Basic Sources of Trouble:PeopleOrganizationExternal InfluencesFacilitiesEquipmentIdeasPoliciesProcessesMaterialsMoney - EconomicsCapacityQualityTimingPersonal Influence"SERIOUSNESS" No. 10 means rejection if "PROBABILITY" is certain (10 x 10).P = Probability (1-10) S = Severity (1-10)7. Make the Final Balanced ChoiceUpdated By:Update Date:Update Rev #:WGCPF-001 page 8 of 9Rev. 518-Nov-03

kwatts:Your first choice is the option that scored the highest on the decision making worksheet.kwatts:Estimate the probablity of an event happening.1 = little likelihood that this event will happen10 = a strong likelihood that this event will happen.kwatts:Estimate the seriousness if the event occurs.1 = little impact if event happens.10 = very serious if event happens.kwatts:Many poor decisions are made because teams fail to consider what could go wrong. Risk Analysis allows the decision makers the opportunity to list any risks that exist with a particular choice. It also provides an opportunity for getting input from people who have to live with the final choice.kwatts:Could the possible choice perform poorly against the mandatory GIVENS? Those that only barely meet the GIVENS criteria should be considered a potential risk.kwatts:Could the possible choice perform poorly against WANTS that have a high Relative Importance Value?kwatts:Are there any external risks with the possible choice such as a compromise on quality or damage to the environment? A checklist is provided to help in brainstorming other risks.kwatts:By considering the benefits (Relative Merit) and the Risks associated with each possible choice, you may decide to:- accept the level of risk.- Commit to the best available choice while directing resources to minimize or manage risk.- Abondon one possible choice in favor of another.- Reject all of the available possible choices.Note: If at all possible, keep your first choice.kwatts:This line is used to record when this form was updated and by whom when it is being used for problem solving.Return to 8D Form Instructions

Plan & Problem PreventionUse your experience to identify parts of your plan that are complex, have tight deadlines, are high impact, or are new. Note: Move your cursor over the cells with red triangles for more information.Consider what might go wrong.Establish which parts most need your attention (Probability and Severity)Identify realistic possible causes. There may be more than one for each key step.How can you keep each possible cause from happening?What is your plan if a problem develops in a key step? Identify the person or position responsible to begin protection actions and what are the cues or dates to kick it off?10. Review, revise, and communicate the final plan.Return to 8D Form Instructions0PLANNING AND PROBLEM PREVENTION WORKSHEET (D6)1. OBJECTIVE OF THE PLAN (Goal with timing):2. KEY STEPS3. POTENTIAL PROBLEMS4. PRIORITY5. POSSIBLE CAUSES6. PREVENTION ACTIONS7. PROTECTION ACTIONS8. CUES (DATE OR EVENT)9. WHOPSRevised By:Revision Date:Revision #:WGCPF-001 page 9 of 9Rev. 518-Nov-03

kwatts:After completing Problem Prevention, update the final plan. Judgment and experience determine what resources and actions are essential. Often limitations in time, money, and personnel will dictate taking risks, since not every conceivable problem can be totally managed.kwatts:Record your 8D number here.kwatts:Your objective should be measurable (quantifiable) and have a due date.kwatts:Develop the steps that must be taken in order to achieve the plan's objective. Construct the steps based on the four phases of the management cycle:- Planning (Plan)- Implementing the Plan (Do)- Recording the results of the implementation phase (Check)- Evaluating the results (Act)THEN:Identify those "KEY STEPS" which are crucial to the success of the plan.Note: In reviewing a plan to see where difficulty or trouble might occur, budget, timing, and quality are good places to start.kwatts:Consider What? Where? When? How Big?kwatts:A team should focus on high priority concerns.P = ProbabilityS = Seriousness

Estimate the probablity of an event happening.1 = little likelihood that this event will happen10 = a strong likelihood that this event will happen.

Estimate the seriousness if the event occurs.1 = little impact if event happens.10 = very serious if event happens.kwatts:Those Potential Problems that scored high are considered "high priority". Use a Cause & Effect Diagram to help you speculate on the possible causes and record them in this column.kwatts:Prevention actions address the cause of a potential problem. "In what ways might we prevent that possible cause from creating the problem?"kwatts:Protection actions serve to minimize the effect or seriousness of a potential problem, should it occur. These actions are a "contingency plan".

"Even if we can control the causes, what are we going to do if something still happens that threatens our objective?

Generally, there are several options and it's important to decide ahead of time which ones seem best.

Note: "Protective" plans are usually more drastic, costly and timely.kwatts:All protection actions must have clearly defined cues which are flagged up when action is to be taken.

"If this happens or this date occurs, this plan will be implemented."kwatts:Define who is responsible for initiating the Protection Action. The authorization must be clear.kwatts:Probabilitykwatts:SeverityReturn to 8D Form Instructions