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Team Members:

Objective:

Open Actions Log

Ref.

No.

Action Details Resp Start Date End Date Report

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G8D REPORTTitle: Date Opened: Last Updated:

Product/Process Information: Organisation Information:

D Symptom(s):

D Emergency Response Action(s): % Effective: Date Implemented:

Verification / Validation:

D1 Team (Name, Dept., Phone) D2 Problem

Champion: Problem Statement:

Team Leader

Team members

Problem Description:

D3 Interim Containment Action(s): % Effective: Date Implemented

D4 Root Cause(s) and Escape Point(s): % Contribution:

Escape Points

D5 Chosen Permanent Corrective Action(s): % Effective:

Verification:

D6 Implemented Permanent Corrective Action(s): Date Implemented:

Validation:

D7 Prevent Actions: Date Implemented:

D7 Systemic Prevent Recommendations: Responsibility:

D8 Team and Individual Recognition: Date Closed: Reported by:

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CAUSE EFFECT DIAGRAM

Man Machine

Environment Material Method

Prod. Engg.

Ford India Page 6 150609804.xls

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Problem Solving Worksheet Step 1 of 4

Problem Statement:

Problem

Description ISLogically could be but

IS NOT

Get

Information

AT

What Object What object has the defect?What objects that are similar in

shape, composition, form or

function could have the defect

but do not?

WH

What Defect What is the defect?What other similar defect(s)

could have been observed but

were not?

Where on

object

Where on the object is the defect

observed (inside/outside, top/

bottom, same/different place,...)?

Where else on the object could

the defect have been observed

but was not?

WHEREWhere first

observed

Where geographically was the

defective object first observed?

Where in the process was the

defective object first observed?

Where geographically could the

defective object have first been

observed but was not?

Where in the process could the

defective object have first been


Where seensince

Where geographically have the

defective objects been observed?

Where geographically could the

defective objects have been

observed but were not?

WHEN

When firstobserved

When in time was the defective

object first observed?

When in the process was the

defective object first observed?When in the life cycle of the

defective object was the defect

first observed?

When in time could the defective

object have first been observed

but was not?

When in the process could the

defective object have first beenobserved but was not?

When in the defective object's life

could the defect have first been


What patternsince

What patterns of occurrence of the

defect have been observed with

respect to time?

When during use of the defective

object is the defect observed?

What patterns of occurrence

could have been observed with

respect to time but were not?

When during use of the defective

object could the defect have been

observed and was not?

How many

affected

How many objects have the

defect?

How many objects could have the

defect but do not?

BIG

What size

What is the magnitude of the

defect in terms of percentages,

rates, patterns, trends, yield,

physical dimensions, etc.?

What magnitude could the defect

have, but does not?

HOWDefects per

objectHow many defects are there per

defective object?

How many defects could there

have been per defective object

but were not ?

TrendWhat is the trend (increasing,

decreasing, cyclical, etc.)?

What could the trend have been

but was not (increasing,

decreasing, cyclical, etc.)?

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Problem Solving Worksheet Step 1 of 4

Problem Statement:

Problem

Description ISLogically could be but

IS NOT

Get

Information

ATWhat Object

WH

What Defect

Where on

object

WHEREWhere first

observed

Where seen

since

WHENWhen first

observed

What pattern

since

How many

affected

BIGWhat size

HOWDefects per

object

Trend

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D3

Decision Making Worksheet Page 1 of _ Decision Making Worksheet

End Result: Choices Available

Criteria

GIVENS: (Mandatory, Measurable, Realistic) Givens Information Y/N Givens Info

a) a) a)

b) b) b)

c) c) c)

d) d) d)

e) e) e)

WANTS: (Objective or Subjective) How Important (1-10)

Wants Information How

Good

(0-10)

Score Wants Informat

a) a) a)

b) b) b)

c) c) c)

d) d) d)

e) e) e)

f) f) f)

g) g) g)

h) h) h)

i) i) i)

j) j) j)

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D3

age _ of _

ion Y/N

HowGood

(0-10)

Score

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D3 - Risk

Decision Making Worksheet

RISK ANALYSIS:

"If we do this what may happen contrary to our interests ?"

SOURCES ATTRACTIVE CHOICE

(CHOICE)P S

1. RISK What characteristics of this choice may fail tosatisfy the GIVENS totally ?

2. RISK What features or characteristics of this CHOICEcompromise or threaten an important WANT ?

3. UNIVERSAL Do you anticipate problems with thechoice in any of the folowing areas ?

People

Organisation

External Influences

Facilities

Equipment

Ideas - Policies - Processes

Materials

Money - Economics

Capacity

Quality

Timing

Personal Interferences

PROCEDURE: Investigate one choice at a time. All threat

assessment by the same individual or group.

"SERIOUSNESS" No. 10 means rejection if a probability is

certain (10 x 10).

P = Probability (1 - 10)

S = Seriousness (1 - 10)

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D4 Rules

Comparative Analysis Job Aid 2

Step 3a : Differences

Differences are facts that are only true of the IS column.

They may be obtained by asking:

What is special, unique or different only of the IS when compared with the IS NOT?

The words from the IS and IS NOT columns should be substituted for the corresponding words in italics .

Step 3b : Changes

Changes are things that have changed in, on around or about the differences.


What has changed in, on, around or about the difference?

The words from the difference column should be substituted for the corresponding words in italics.

The date on which the change took place should also be entered into the date column.

Step 4 : Developing Possible Cause "Change - How" Theories

Theories are fully rounded possible causes, rather that probable causes, that may have created the defect.


How could this change have caused the problem statement?

The words from the changes column and the problem statement should be substituted for the corresponding

words in italics.

Step 5 : Testing the Theories

Tests of the theories are destructive critical evaluations of the developed theories against the sets of IS and IS

NOT columns.


If the possible cause theory is the cause of the problem statement why is it only the IS and never the IS NOT?

The words from the possible cause theory, the problem statement, the IS column and the IS NOT column should

be substituted for the corresponding words in italics.

If the possible cause theory logically explains the information in the IS and IS NOT columns then put a "+" in the

test matrix.

If the possible cause theory cannot logically explains the information in the IS and IS NOT columns then put a "-"

in the test matrix.

If it is unclear whether the possible cause theory logically explains the information in the IS and IS NOT columns

then put a "?" in the test matrix.

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D4

Problem Solving Wor"Some changed gradually"

Differe

Problem Description IS

but

IS NOT Differences

What Object

What Defect

Where on object

Where first observed

Where seen since

When first observed

What pattern since

How many affected

What size

Defects per objectTrend

Problem Statement: B376 & B226 engines getting hydrolocked due towater wading.

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D4

sheet Step 2 of 4 Problem Solving Worksheet S Test causes for probability (+, - or ?)

nces and Changes

a) b) c) d)

Changes Date

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D4

tep 4 of 4

e)

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D4 - Possible causes

Problem Solving Worksheet - Step 3 of 4

Possible Causes

List Possible Cause Theories

1

2

3

4

5

6

7

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D5

Decision Making Worksheet Page 1 of _ Decision Making Worksheet

End Result: Choices Available

Criteria

GIVENS: (Mandatory, Measurable, Realistic) Givens Information Y/N Given

a) a) a)

b) b) b)

c) c) c)

d) d) d)

e) e) e)

WANTS: (Objective or Subjective)How

Important

(1-10)

Wants Information How

Good

(0-10)

Score Wants Inf

a) a) a)

b) b) b)

c) c) c)

d) d) d)

e) e) e)

f) f) f)

g) g) g)

h) h) h)

i) i) i)

j) j) j)

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D5

of _

Y/N

Score

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D5 - Risk

Decision Making Worksheet

RISK ANALYSIS:

"If we do this what may happen contrary to our interests ?"

SOURCES ATTRACTIVE CHOICE

(CHOICE)P S

1. RISK What characteristics of this choice may fail tosatisfy the GIVENS totally ?

2. RISK What features or characteristics of this CHOICEcompromise or threaten an important WANT ?

3. UNIVERSAL Do you anticipate problems with thechoice in any of the folowing areas ?

People

Organisation

External Influences

Facilities

Equipment

Ideas - Policies - Processes

Materials

Money - Economics

Capacity

Quality

Timing

Personal Interferences

PROCEDURE: Investigate one choice at a time. All threat

assessment by the same individual or group.

"SERIOUSNESS" No. 10 means rejection if a probability is

certain (10 x 10).

P = Probability (1 - 10)

S = Seriousness (1 - 10)

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