FORM DESCRIPTION

Corrective Action Request (CAR)

Page 1 of 4
Form No.: F-034
Revision: 1
Release: 19-Dec-11

8-Discipline Steps
Date Open: 12/3/14

Recurring Issue: Yes

D1.: Process Owner:

AK Steel

8-D Team: Larry Davis, Eric Krause, Daryl Underwood

Concern Found:
Part No.: 2123/7478

Responsible
Shift:
Area:
Part Name: F-25 and F-15 BSO

Quantity: 4 cars at BMW. 2

full lifts blocked at GSC

Customer:
BMW

Customer Reference No. :

(ex. Q-Alert No.)

D2.: Problem Description: AK-4

2123: 2 scrapped cars from stamp date 11/8/14 (BMW QA on 11/13/14))

2123: 1 scrapped car from stamp date 11/15/14 (BMW QA on 11/19/14)
7478: 1 scrapped car from stamp date ____ (BMW QA on 11/17/14)
7478: 1 Lamination repaired. Stamp date 11/24/14 (BMW QA on 11/30/14)

FORM DESCRIPTION
Corrective Action Request (CAR)

Page 2 of 4
Form No.: F-034
Revision: 1
Release: 19-Dec-11

8-Discipline Steps

D3.: Containment Activity:

100% Post Cognex review of existing inventory
Initial 12/3/14
All material past EG has been post Cognex reviewed (Items 247034/035 & 266478/479) and that
was completed 12/11/14.
Problem-Solving Tool Used: Streaming video from the production run manually reviewed for
verification of accuracy of initial inspection.

D4.: Root Cause:

SEM analysis from Research indicates two different conditions were found. SC#16076602A was a Hot Strip Mill gouge with spongy iron in it and the other SC#159051-04A was a
post pickle tank gouge with no oxide in it. These two coils were green tagged for other
conditions but these were not seen by inspection due to being subsurface as a result of
cold reduction at the cold mill and being coated over at the EG line.
Root Cause of non-detection:
Some gouges were observed during inspection and cropped out or stenciled to Gonvauto

FORM DESCRIPTION
Corrective Action Request (CAR)

Page 3 of 4
Form No.: F-034
Revision: 1
Release: 19-Dec-11

8-Discipline Steps
to crop out but some were below the surface and did not get cropped out as confirmed in
the Research reports.
D5.: Corrective Action:
Changes to inspection criteria will result in increased stoning frequency at the TM and the CM. Take
every 3rd coil at CM off line to a cradle roll and then stone one roll circumference. Post Cognex
review all future orders and inspect same as a hood outer. New inspection criteria for all body side
outer material ahead of EG was updated on 12/09/14. Quality Alert # 19-QA-14-02 issued to

Precision Strip on 12/5/14 to enhanced inspect for roll marks and laminations and provide samples to
CTS if found.

D6.: Verification of Corrective Action:

Quality alerts and enhanced inspection routed verified complete on 12/15/14
D7.: Preventive Action:
On-going Continuous Improvement Plans in place for HSM Gouges and Caster Laminations
updated Monthly will be reviewed during the meeting at Gestamp on 12/17/14.

Benefits of Action Taken:

Enhanced inspection and awareness of conditions at EG and PRMD.
Target Date for
Scheduled
Closed
Completion: 12/17/14
Follow-up Date: 12/10/14
Date:
D8.: Team Recognition:
Eric Krause, Chris Newkirk, Robert Fehn, Daryl Underwood, Larry Davis

Management Approvals:

Before you submit the CAR-8D, please ensure the following have been addressed or considered.

Considerations for CAR-8D closure (check):

Can this corrective action be applied to similar products or processes (if yes,

Yes
X

No

N/A

FORM DESCRIPTION
Corrective Action Request (CAR)

Page 4 of 4
Form No.: F-034
Revision: 1
Release: 19-Dec-11

8-Discipline Steps
describe & show evidence of applicability. If no, describe reason)?
If a mistake proofing activity was defined can it be applied to similar products or
processes (if yes, describe & show evidence of applicability. If no, describe
reason)?

Are there any revisions to be made to IMS documents (submit revision)?

Are there updates required to the FMEA, Control Plan, Inspection Plans/Reports
(submit revisions)?

X
X

Do the actions meet the Containment release requirements (if no, describe
reason)?
Has training occurred to employees & has the verification been confirmed that the
employees trained understood the directive?
Has the surface data, destruct or dimensional data been review & is stable (if no,
describe)?
Other (explain):