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  • Drill Deep Root Cause Analysis Worksheet

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    Lipeca
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    The document details a 5 Whys analysis of a defect where a windshield was missing a red dot sticker needed for the wiper blade. The planning process did not adequately predict or prevent the defect. Visual inspection did not detect the missing dot and manufacturing instructions lacked detail. Approval was granted for a detection system but one had not yet been installed across production lines. Key findings were that inspection of the part in the rack was inadequate and the dot was difficult to see, suggesting elimination of the dots or improving detection.

    Original Description:

    Análisis de causa raiz

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    The document details a 5 Whys analysis of a defect where a windshield was missing a red dot sticker needed for the wiper blade. The planning process did not adequately predict or prevent the defect. Visual inspection did not detect the missing dot and manufacturing instructions lacked detail. Approval was granted for a detection system but one had not yet been installed across production lines. Key findings were that inspection of the part in the rack was inadequate and the dot was difficult to see, suggesting elimination of the dots or improving detection.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as xls, pdf, or txt
    522 views1 page

    Drill Deep Root Cause Analysis Worksheet

    Uploaded by

    Lipeca
    The document details a 5 Whys analysis of a defect where a windshield was missing a red dot sticker needed for the wiper blade. The planning process did not adequately predict or prevent the defect. Visual inspection did not detect the missing dot and manufacturing instructions lacked detail. Approval was granted for a detection system but one had not yet been installed across production lines. Key findings were that inspection of the part in the rack was inadequate and the dot was difficult to see, suggesting elimination of the dots or improving detection.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as xls, pdf, or txt
    of 1

    Drill Deep Worksheet

    Date:

    10/01/04

    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 process informational 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

    Failure to follow instructions

    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 process standardized work and


    error proofing

    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 process detection &
    responsiveness

    Q4
    Q5
    Q-RC

    What are the key findings based on


    this quality issue and the above 5
    Why analysis?

    K1
    K2
    K3

    K4
    K5

    337202361.xls

    Revision 5.0 03/08/04

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