Instructions Sheet 2010 KnowWare International Inc

1. Select the template sheet --> 8D Report

2. Cells may have hidden comments to help in completing the template 2253 S Oneida St Ste 3D
Denver, CO 80224

www.qimacros.com/quality-tools/toyota-a3-report-template/ Licensed users:

A3 Report May update this file
0. Determine immediate actions required (A5) May copy this file
1. Establish the Team May share completed files with co-workers, suppliers and customers
2. Define the problem (A10)
3. Develop Interim Containment Actions (A103) Unlicensed users:
4. Identify and Verify Root Causes (RCA) (use Excel's Drawing tools to complete fishbone) May receive and review completed templates created by licensed users
Excel 97-2003 - Click on View-Toolbars-Drawing May NOT use this template to perform their own analysis without a license
Excel 2007-2010 - Click on Insert - Shapes
5. Identify Permanent Corrective Actions (PCAs) To purchase a license:
6. Identify and Verify the PCAs (A176) http://www.qimacros.com/store
7. Prevent Recurrence (A187) Email orders@qimacros.com
8. Honor the Team (A230) Call 888 468 1537 - (303) 756 9144
Fax a PO to 888 468 1536 - (303) 756 3107
Tracking Number: Customer Number: Response Due Date:
Step 0 1 2 3 4 5 6 7 8
Implement
Establish the State the Containment Root Cause Corrective Corrective Prevent Recognize
Action Planning Team Problem Plan Analysis Actions Actions Recurrence Team Efforts
0 Planning Stage Is an Emergency Response Action Needed?
What Who When

1 Establish the Team Team Goals:

Team Objectives:

Department Name Skills Responsibility

2A Problem Definition Sketch/Photo of the problem

Part Number(s):

Customer(s)

List data and documents needed

Action Plan to collect information needed

Prepare Process Flow Diagram of Problem

 2B IS IS NOT
Who Who is affected? Who is not affected?

Who first observed the problem? Who did not find the problem?

Reported to whom?

What What type of problem is it? What does not have the problem?

What (part, lot, etc.) has the problem? What could be happening but is not?

What is happening with process? What could be the problem but is not?

Physical evidence of the problem?

Why Why is this a problem? Why is it not a problem?

Is the process stable?

Where Where was the problem observed? Where could the problem be, but is not?

Where does the problem occur? Where else could the problem be, but is not?

When When was the problem first noticed? When could be problem have been noticed?

When has it been noticed since?

How Much Quantity of problem (PPM)? How many could have the problem but don't

How much is it costing? How big could the problem be, but is not?

How Often What is the trend? What could the trend be, but is not?

Has the problem occurred previously?

2C Describe the Problem

3 Develop Interim Containment Actions

4A Identify and Verify Root Causes (RCA)

4A Cause Effect Diagram

How is it made? Why did it get out?
People Materials Machine People Materials Machine

Problem

Method Environment Measurement Method Environment Measurement

4B Five Why Analysis

1. Why did this happen?

2. Why?

3. Why?

4. Why?

5. Why?

4C Action Plan
What How Who When Where Why
5 Identify Permanent Corrective Actions (PCAs)

6 Implement and Verify the PCAs

7 Prevent Recurrence

7A Replicate to Similar Systems

Process/Item Who? When?
7B Review Documents and Systems
Document Who? Planned Completion Actual Completion
Management System Manual

Manufacturing Work Instructions

Inspection Work instructions

Process Flow Charts

Process Control Plans

Design FMEA

Process FMEA

Gages

PPAP

Engineering Change Approval

8 Cost \ Benefit Rollup - Saved / Loss Avoidance

Was the problem solving exercise effective? Has it been verified with follow-up?
Yes/No Signature / Title / Date Findings
Actions
Containment/Corrective
Action # Problem Action How Verified Action Who Planned Actual Status