430567609.

xls QRCM Summary

QRCM Problem Solving Report Tracking No.

Date Opened
Last updated:

D0 - Customer Reported problem:

Date Reported: Qty Rejected: Customer Reject No.

Customer Name: Customer Contact: Phone No.
Meritor P/N: Customer P/N:
D1 - Team
Role Name Function Phone Email
Champion
Leader
Member
Member

D2A - Problem Statement

D2B - Problem Description

Brief Problem Description
What:
Where:
When:
How big:
D3 - Containment Action(s)
No. Action Description Resp Date Verification (Methods and Results)
Initiated Comp

D4A - Occur root cause

Verification (Methods and Results) Date Verified:

D4B - Escape Root Cause

Verification (Methods and Results) Date Verified:

D5/D6 - Permanent corrective actions (occur and escape)

No. Action Description Resp Date Validation (Methods and Results)
Target Comp

D7 - Preventive Actions
No. Action Description Resp Date Validation (Methods and Results)
Target Comp

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 430567609.xls QRCM Summary

D8 - Team/ Individual Recognition & Approval

Approval: (electronic approval is acceptable if kept as record attached to the 8D summary)

Signature Name Title Date

Quality Lead

Operations Lead
If applicable

If additional signatures required

If additional signatures required

If additional signatures required

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 430567609.xls Action Plan

Action Plan Summary

Tracking #: Champion: G - Complete
Y - Needs Attention
Subject: Start Date: Updated: R - Needs Urgent Attention

Number Issue / Action Item Responsible Target Status Action Status / Results
Completion
Date

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 430567609.xls Action Plan

Action Plan Summary

Tracking #: Champion: G - Complete
Y - Needs Attention
Subject: Start Date: Updated: R - Needs Urgent Attention

Number Issue / Action Item Responsible Target Status Action Status / Results
Completion
Date

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 430567609.xls Alert

QUALITY ALERT
Tracking No: Date Initiated:

Part No/Family Affected: Date expires:

Customer: Issued by:

Concern Description

Good Part Bad Part

Picture, sketch or description Picture, sketch or description

CONTAINMENT REQUIREMENTS
NO. LOCATION AND/OR DESCRIPTION OF SPECIAL ACTIONS START RESP.
PROCESS POINT DATE/TIME

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430567609.xls Containment Data

CONTAINMENT CHART
Tracking No.
Date Initiated
Please follow the quality alert
for containment criteria

LOCATION RESPONSIBILITY DATE

SHIFT

@ Inspected
Customer
Rejected

In transit to Inspected
Customer
Rejected

Supplier Inspected

Rejected

In transit Inspected
from
supplier Rejected

In plant Inspected
location 1
Rejected

In plant Inspected
location 2
Rejected

In plant Inspected
location 3
Rejected

In plant Inspected
location 4

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430567609.xls
In plant Containment Data
location 4
Rejected

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430567609.xls 5-why

5-WHY ANALYSIS

Problem Statement:

Why

Because the

Why

Because the

Why

Because the

Why

Because the

Predict - Why did the planning process not predict the nonconformance?

Why

Because the

Why

Because the

Why

Because the

Why

Because the

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430567609.xls 5-why

5-WHY ANALYSIS

Problem Statement:

Prevent - Why did the manufacturing process not prevent the nonconformance?

Why

Because the

Why

Because the

Why

Because the

Why

Because the

Protect - Why did the quality process not protect from the nonconformance?

Why

Because the

Why

Because the

Why

Because the

Why

Because the

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 430567609.xls Is-Is Not

Problem Statement:

Problem Description:
Last Updated:

Is Is Not Get Information Differences Changes

WHAT
What object has defect? (part / family
name)
What object has defect (part number)

What portion of the overall object has

the defect (specific component if you
are describing a large system or
assembly))
What deviation against what spec.

WHERE
Where the concern is on the object (be
specific - LH/RH, inside/Outside,
top/bottom, front/rear, location, which
end, scatter or concentration diagram)

Where is the concern on the vehicle?

(LH/RH, front/rear, side to side,
top/bottom,
At what place in the process the defect
is first identified? (exact location in their
process - exact process step)

Where seen? - (specific location)

Where seen - geographical location -
please be as specific as possible

WHEN
When was the problem initially
reported? (date, time)
When was the problem first
experienced / observed (date operator,
machine)
When else this problem was seen (if
multiple occurrence, then attach a
detailed spreadsheet in the workbook
and narrate book-ends here)

When in the lifecycle the problem has

occurred? (years in service, mileage,
etc.

HOW BIG
Describe size of the problem on an
individual component) - magnitude,
size, spread (how much of each part
affected), severity, penetration, etc. - If
data are not 100% factual, actions are
to be defined to get facts)

Number of problems on each part or

individual assembly
Number of problem on each individual
customer assemblies
Total number of components affected

% of product or group affected

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 430567609.xls Hypothesis Development

PROBLEM SOLVING WORKSHEET Probability

List Change How Theories
difference or change statement (fact)+ how (engineering rationale) = problem statement

A 0

B 0

C 0

D 0

E 0

F 0

G 0

H 0

I 0

Click to RunMacro to
Update Trial Run of
Possible Causes

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430567609.xls
Click to RunMacro to Hypothesis Development
Update Trial Run of
Possible Causes

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430567609.xls Hypothesis Development

PROBLEM SOLVING WORKSHEET

Trial Run of Possible Causes
Is Statement Theory "A" explains the "Is" statement?
True or False

10

11

12

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430567609.xls Hypothesis Development

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

TOTAL 0

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 430567609.xls Hypothesis Development

Theory "B" explains the "Is" statement? Theory "C" explains the "Is" statement?
True or False True or False

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430567609.xls Hypothesis Development

0 0

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 430567609.xls Hypothesis Development

Theory "D" explains the "Is" statement? Theory "E" explains the "Is" statement?
True or False True or False

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430567609.xls Hypothesis Development

0 0

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 430567609.xls Hypothesis Development

Theory "F" explains the "Is" statement? Theory "G" explains the "Is" statement?
True or False True or False

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430567609.xls Hypothesis Development

0 0

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 430567609.xls Hypothesis Development

Theory "H" explains the "Is" statement? Theory "I" explains the "Is" statement?
True or False True or False

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430567609.xls Hypothesis Development

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 Cause and Effect Diagram
Measurement Materials Method

Problem
Statement

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 Environment Manpower Machine

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 DETERMINING SYSTEM INADEQUACY
RESPONSIBLE FOR HUMAN ERROR

Was support provided to No SUPPORT FAILED

perform task?
Personnel No
Equipment Was type / capability / amount /
Material Yes condition of support provided Yes Support not
Supplies sufficient to correctly perform responsible
the task?
Services / facilities

No STANDARD FAILED
No
Do standards / procedures Are they clear / practical Yes Standards /
exist for the task?
Yes procedures not
responsible

No TRAINING FAILED

HUMAN Did individual receive

training on how to perform
No

ERROR the task?

Yes Was training correct, complete,
and sufficient for performance
Yes
Training not
to standard? responsible

No LEADER FAILED

No
Yes Did Leader(s): Yes
Did leader(s) enforce Make on-the spot corrections?
standards?
Leader not
Emphasize by the book
responsible
examples and opportunities?
Take action when appropriate?

INDIVIDUAL FAILED

Did individual know Yes

standards and was he
trained on standards?
Yes Did individual elect not to follow No
the standard (self-discipline)?
Individual not
(Attitude, haste, overconfidence,
self-induced fatigue) responsible

No

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 430567609.xls 3x5

3 x 5 Worksheet

5 Whys Corrective Action Owner Due Date

P1
Why did the planning process not predict
the non-conformance?
P2

P3
Predict
P4
Planning process -
informational content P5
in FMEAs and CPs

P-RC

M1
Why did the manufacturing process not
prevent the non-conformance?
M2

M3
Prevent
M4
Manufacturing process -
standardized work and
error proofing M5

M-RC

Q1
Why did the quality process not protect
from the non-conformance?
Q2

Q3
Protect
Q4
Quality process -
detection &
responsiveness Q5

Q-RC

What are the key findings based on this K1

quality issue and the above 5 Why
analysis? K2

K3

K4

K5

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 430567609.xls Read-Across Matrix

3 x 5 Matrix & Read Across

Meritor Division 8D Tracking No. O Original Product Line and Location
Meritor Location Date Opened: X Product Line and Location with Similar Process
Meritor Product Date Last Updated: N/A Not Applicable
Complete and 3rd party / Verified
Complete & Supplier Verified Only

Not Completed

t
Plan
Systemic Issue Systemic Systemic

4
1

3
Champion Due Date

t
t

Plan
Plan

Plan

Plan
in
5 Why? Root Cause (RC) Corrective Actions

With
PREDICT

Why did the planning

process not predict the
nonconformance? Document Verification/ Validation

PREVENT
Why did the
manufacturing process
Document Verification/ Validation
not prevent the
nonconformance?

PROTECT
Why did the quality
process not protect the
customer from the non-
Document Verification/ Validation
conformance

Key Findings

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