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Fill 8D reports (Part 1)

KZK Solutions /kzoli62/
Published by Z. Kovács in Quality · 5 May 2021
Tags: QA8D
In this tutorial, I will show you how to complete 8Ds according to the changed (tightened) VDA requirements. This was because one of our customers did not have enough capacity to process the 8Ds and there were too many 8Ds rejected due to the low score.
I was able to help with both the number of complaints processed and the improvement of the score.
I have developed the material below as an educational material for them.
During the training, I go through the upload order of the BMW B2B portal, but other portals also include these points, with minimal variation.
Due to the length of the topic, I divided the presentation into two parts.

General information

B2B portal

Complaints opened on the portal must be uploaded as described in the presentation. All the points described have to be done because they all bring points.
I will try to describe it in as much detail as possible so that we can reach the maximum of 10 points available.
I will also attach a 9.34 point 8D and include what I missed in the presentation.
It is not mandatory, but I suggest using the wording in the sample, as I have agreed with my evaluation colleagues at BMW.
I also recommend uploading the non-mandatory documents, because this will have a positive effect on the evaluation and will bring extra points.
When describing the team, the following must be filled in:

Team leader

Surname: Kovács  
First name: Zoltán  
Phone+36 30 …-….  
eMail*… . …@...-automotive.com

Team

Name   Function   Email   Phone
Supporting:
QA Supervisor  
Members:
Customer Relationship (CS)    
Process Engineer (PE)    
Customer Quality Engineer (CQE)    
QA Team Leader  
Independent moderator:
Valid Group  
Independent evaluator:
Daimler Engineering Supervisor  

D2.1 – Complaints

It includes:

  • The date the error was detected
  • Problem Description
  • Who and how many pieces he complained about
  • Affected factories
  • Who and how notified the factories concerned. (If this was done in an Email, the Email must be attached.)
  • List of documents
 
Required documents:

  • PB xxxxxxxxx.pdf   – Complaints (Prüfbericht)
  • PB xxxxxxxxx_yyyyyyyyyy.pdf   – Presentation (detailed later)
Optional documents:

  • Warnung_xxxxxxxxxx.pdf  – Notify affected factories by Email
After naming the documents, you should always clearly describe what the file name covers.

D2.2 – Supplier problem description

It includes:

  • Number of pieces claimed by customer
  • Error description (If possible, a good and bad image should be attached.)
  • Based on the yes / no analysis, we come to the following problem findings:

    • Where and how many defective products were found
    • Where the faulty piece was made
    • Which product family is affected by the error
    • A one-time error or such problem has occurred
    • Yes / No analysis attached (PB xxxxxxxxx_yyyyyyyyyy.pdf page 3)

Next, we need to list what analyzes we performed on the returned product.

  • Make sure the part's production history is clear and there have been major events in the same production period

    • The measurement results show that the production of the part in question was OK (Original measurement.jpg)
    • It must be ascertained whether there has been a systematic defect in the process during the manufacture of the part in question.

  • There was no problem in the process at the time of production (yyyy.mm.dd) (Maintenance.jpg)
  • We checked that the complained part in the same function test that it originally passed:

    • Check whether the complained part is automatically marked as defective by the function test.
          - EOL indicates faulty.

  • Responsible:

    • Name - Function (PE)

  • Impact of issue:

    • Mild - e.g. beauty defect, secondary or convenience function
    • Medium - primary function
    • Severe - risk of accident, complete loss of function

  • List of documents
 
Required documents:

  • PB xxxxxxxxx.pdf   – Complaints (Prüfbericht)
  • PB xxxxxxxxx_yyyyyyyyyy.pdf   – Presentation (detailed later)
 
Optional documents:

  • Original measurement.jpg   – Original measurement protocol
  • Maintenance.jpg  – Check for process problem
  • Soll.jpg    – Good part
  • Ist.jpg    – Defective part

Immediate action

The method of immediate action is always sorting !!!
Attention !!!
The maximum score is given only if we give between D3 and D6 how the number of defective pieces changes with each measure. A graphical representation is proposed for this.

D3.1 – Quality Alert

It includes:

  • Create a quality warning (Warning_PB xxxxxxxxx.pdf), train employees according to QA (Training_mm_dd.pdf)
  • Method:

    • Sorting or continuous inspection during production. Workers should visually inspect the product for the defect described in the QA.

  • Efficiency:

    • The measure was successful / (was not effective) because BMW / SMR did not find (/ x) defective parts after Cleanpoint (yyyy.mm.dd.).
    • Visual inspections showed a statistically 10% slippage, a method we also agreed with BMW.
    • Employees know the image of the error and pay attention to it.

  • Risk analysis:

    • The risk of this measure is low, an error can only occur if workers do not comply with the regulations.

  • Possible side effects:

    • No side effects are known. (It is possible that if workers pay more attention to this error image during production, production efficiency may decrease.)

  • List of documents
Required documents:

  • PB xxxxxxxxx.pdf   – Complaints (Prüfbericht)
  • PB xxxxxxxxx_yyyyyyyyyy.pdf   – Presentation (detailed later)
  • Training Training_hh_nn.pdf   – Training protocol

  • Responsible:

    • Name - Function (CQE)

D3.2 – Stock sorting

It includes:

  • When, how many parts were sorted. How many faults were found, resp. was it all good.
  • Documents:

Required documents:

  • Sorting PB xxxxxxxxx hh-nn.pdf  – Sorting report

Optional documents:

  • AA PB xxxxxxxxx Sorting.pdf  – Sorting work instruction

  • Responsible:

    • Name - Function (CQE)

D3.3 – Sorting at the customer

It includes:

  • Who and with whom agreed, whether it is necessary or not.
  • If necessary, the same documents as described in D3.2 should be attached.

D3.4 – Sorting of transit parts

This is forgotten many times and many. Because of this, evaluators are paying close attention to this.

It includes:

  • Who and with whom agreed, whether it is necessary or not.
  • If necessary, the same documents as described in D3.2 should be attached.

Causes of error

Points D4 - D5 - D6 must always be divided into 4 parts !!!

These are the following:

  • Cause / origin

    • Technical
    • System
    • Undiscovered

  • Technical
  • System

As the above points have to be divided into four parts, the 5 Why analysis should also be prepared separately for each point. On page 32, I’ll show you a sample of what this might look like.
For the 5 why analysis, it is not mandatory to go down to all 5 Why levels.
To be specified at sub-items D4 in case of supplier error. To do this, check the supplier error field.

Attention !!! All the reasons that can really play a role should be listed !!!

A solution to these reasons should also be proposed in sections D5 and D6.

Failure to do so will result in a point deduction !!!

A reference to the operator and its inattention should be avoided if possible !!!

If indeed the operator made a mistake, there must be a reason for it.

D4.1 – Technical cause of origin

It includes:

  • Introductory text (Based on the analysis of Ishikawa and 5 Why, the following is the technical reason for the origin)
  • List of reasons
  • Documentations:

PB xxxxxxxxx_yyyyyyyyyy.pdf  –   Presentation, indicating on which page the the following information:
    - Layout
    - Ishikawa
    - 5 Why analysis

  • Risk analysis:

  • If reference is made to a lack of field risk, reasons must be given as to why and where the information comes from.

D4.2 – Reason for formation of system

It includes:

  • Introductory text (Based on the analysis of Ishikawa and 5 Why, we get the following for the reason of the formation system)
  • List of reasons
  • Documentations:

    • PB xxxxxxxxx_yyyyyyyyyy.pdf  –   Presentation, indicating which page contains the following information:
         - Layout
         - Ishikawa
         - 5 Why analysis

  • Risk analysis:

  • If reference is made to a lack of field risk, reasons must be given as to why and where the information comes from.

D4.3 – Technical reason for undiscovered

It includes:

  • Introductory text (Based on the analysis of Ishikawa and 5 Why, the technical reason for undiscovered is the following)
  • List of reasons
  • Documentations:

    • PB xxxxxxxxx_yyyyyyyyyy.pdf  –   Prezentáció, megadva melyik oldalon találhatók a következő információk:
         - Layout
         - Ishikawa
         - 5 Why analysis

  • Risk analysis:

  • If reference is made to a lack of field risk, reasons must be given as to why and where the information comes from.

D4.4 – Reason for undisclosed system

It includes:

  • Introductory text (Based on the analysis of Ishikawa and 5 Why, we arrive at the reason for the undiscovered system)
  • List of reasons
  • Documentations:

    • PB xxxxxxxxx_yyyyyyyyyy.pdf  –   Presentation, indicating which page contains the following information:
         - Layout
         - Ishikawa
         - 5 Why analysis
  • Risk analysis:

  • If reference is made to a lack of field risk, reasons must be given as to why and where the information comes from.

In general, here the reasons for the system include FMEA, CP and possibly shortcomings in work instructions.
In the next part of my series, I will continue with D5 - Corrective Actions.


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