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Systematic Cause Analysis Technique ChartFull description
Drill Deep Worksheet Date Date::
10/0 10/01/ 1/04 04
Issue title: (Part Number) Wind Shield Missing Red Dot Sticker Customer concern: Customer received a windshield where the left side Red Dot was missing to set the wiper blade. Defect on part: Missing red wiper dot sticker
5 Whys
Why did the planning process not predict the defect?
Predict Planning Planning process informa inf ormational tional content content in FMEAs and CPs
Corrective Action
Owner
Due Date
Simpson
10/18/04
P1
Recommended action not completed Add recommended actions to Quality as timely as expected Boss chart to track progress
P2
No scheduled review of FMEA for updating recommended actions
P3
Waiting on approval for spending Approval has been granted for capital to install dot detection system speding capital for detection system
Sislack
09/27/04
P4
Scope of project not completely defined
Krusty
10/31/04
P5
Difficulty in accomodating adjustable Define scope of detection system, design for multiple parts send for quote
Flanders
10/31/04
Detection system to be standardized Pending removal of dots; install on all production lines applying red standard detection system on all dot production lines
Skinner
11/30/04
P-RC
Implement FMEA review for NMI projects after launch based on lessons learned from production runs
Define scope of detection system, send for quote
Burns
M1
Visual inspection did not detect missing dot
M2
Fail Failur ure e to to fol follo low w inst instru ruct ctio ions ns
Prevent
M3
Lack of detail (pictures) in assembly instruction for inspection of red dots
Update WI to include pictures of inspection areas
E. Cartman
10/07/04
Manufacturing Manufacturing process process standardized work and error proofi proofing ng
M4
No poke-yoke in priming/assembly equipment to detect missing dot
Pending removal of dots; install standard detection system on all production lines
K. Brovlowski
11/30/04
M5
Waiting on approval for spending Approval has been granted for capital to install dot detection system speding capital for detection system
S. Marsh
09/27/04
Q1
Visual inspection of part in rack not adequate
Add offline inspection of product on dock prior to shipment
Garrison
09/25/04
Q2
Left wiper dot not easily visible in rack
Verify left dot by elevating rack for inspection
Chef
09/25/04
Q3
Dot is at center of rack and partially primed over
Suggest elimination of left dot or all dots; including existing programs/launches using dots
Kenny
Why did the manufacturing process not prevent the defect?
M-RC
Why did the quality process not protect the customer from the defect?
Protect Quality Quali ty process detec tection & responsiveness
Q4 Q5
Q-RC
What are the key findings based on this quality issue and the above 5 Why analysis?
