8D report

Customer plant CK3 Internal claim # Date of claim 7/19/2023

Customer contact Ivan Temix Nidec Site Date of QR
Customer reference Author Benito Sanchez Update of QR

QUICK RESPONSE (D1-D3)

This document must be issued within 24 hours after claim notification

D 1. Description of the problem

1.a What is the problem ? Use 5W+2H to describe what is the current situation.

What happened? Paros maquina pieza se atora.

Problem description Insulator lado A con rebaba

Why is it a problem? Genera micro paros y baja la produccion.

Incident type Internal claim
Part number M0027032 When did it happen? 7/19/2023
Part description Insulator Who detected it? Línea de producción CK3-L1
Traceability of nok parts 7-Jul-23 Where was it detected? CW010
Recurrence non reccurent How was it detected? Area de Stator
Previous QN if recurrence non reccurent How many parts ? 15
Defect S/R no
picture / sketch

picture / sketch
nok part

ok part

1.b Problem solving team

Name Position Location Telephone Email

1.c Tools to use

FTA 5why's LLC Audit Other

1.d First analyse of problem / potential root causes

Falta de ajuste en el porceso

Samples of nok parts required in plant for analyse NG part ETA and Tracking number

D 2. Risk on similar products and processes

Walk the process with Process FMEA & Process Control Plan. Was the risk considered?

Can this defect happen on similar parts ? Comments (compulsory if yes)

Other family product
Other line
Other tools/work station
Other

D 3. Containment
Actions to detect all non-conforming parts in the process flow (add additional sheets if neded)

Sorting criterias (add additional sheets if neded)

Location in the supply chain Nb to be sorted Nb parts sorted Nb nok parts ppm Date Resp.
Parts at customer (Car maker)
Parts at customer (Tier 1)
Parts in Nidec plant
Parts at Nidec logistics platform
Parts in transport / transit
Parts at supplier / supplier platform

How are the ok parts identified ?

How are the ok paletts identified ?
First contained shipment information

Immediate actions to prevent production and delivery of nok parts ?

Actions Resp. Date plan. Date clos.

Ref. P102.01X F102.01E

 ASSIGNMENT / BREAKDOWN
WHAT ? WHO? [8] Due date [9] Done date [10]
Confirm actual situation (Quick Response PDCA) [1]
Make Factor Tree Analysis for Occurrence [2]
Make Factor Tree Analysis for Non detection [3]
Confirm root cause with 5 Why's [4]
Implement action plan [5]
Confirm efficiency of Action plan [6]
Standardize and Generalize [7]

N° ASSIGNMENT [11] RESULTS [12] WHO [13] Due date [9] Done date [10]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Ref. P102.01X F102.01E

 Ishikawa Diagram

Customer plant #VALUE! Internal claim # #VALUE! Date of claim #VALUE!

Customer contact #VALUE! Nidec Site #VALUE! Date of Ishikawa

Customer reference #VALUE! Author #VALUE! Update of Ishikawa

Material Environment Method

Machine Measurement Manpower

Ref. P102.01X F102.01E

 Factor Tree Analysis Occurrence
Customer plant Internal claim # 0 Date of claim #VALUE!
Customer contact Nidec site 0 Date of FTA
Customer reference Author Benito Sanchez Update of FTA

Problem description: #VALUE!

Factor Direct
4M Factors Control point Standard OK parts NOK parts Std meet Std OK
Nb link ? Potential Root Cause
OCCURENCE
WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
1 Yes No Yes
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
2
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
3
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
4
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
5
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
6
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
7
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
8
STD number and revision level ?

All validated causes (direct link or doubt) must lead to a 5 Why's analysis

Ref. P102.01X F102.01E

 Factor Tree Analysis Non Detection
Customer plant Internal claim # 0 Date of claim #VALUE!
Customer contact Nidec site 0 Date of FTA
Customer reference Author Benito Sanchez Update of FTA

Problem description: #VALUE!

Factor Direct
4M Factors Control point Standard OK parts NOK parts Std meet Std OK
Nb link ? Potential Root Cause
OCCURENCE
WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
1 Yes No Yes
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
2
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
3
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
4
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
5
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
6
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
7
STD number and revision level ?

WHAT is the STANDARD method/value? GOOD part taken as reference / GOOD BAD part taken as reference / BAD situation
situation taken as reference: taken as reference:

WHO is trained to the STANDARD?

WHERE is the standard available? Measurement on Real Parts / Condition of Real Measurement on Real Parts / Condition of Real
Situation: Situation:
8
STD number and revision level ?

All validated causes (direct link or doubt) must lead to a 5 Why's analysis

Ref. P102.01X F102.01E

 5 Why's
Customer plant CK3 Internal claim # 0 Date of claim 7/19/2023
Customer contact Ivan Temix Nidec site 0 Date of 5 why's
Customer reference 0 Author Benito Sanchez Update of 5 why's

Problem description : Insulator lado A con rebaba

Potential Root Cause Nb. 1st WHY? How was verified? 2nd WHY ? How was verified? 3rd WHY ? How was verified? 4th WHY ? How was verified? 5th WHY ? How was verified?

OCCURENCE

NON DETECTION

SYSTEMIC

Ref. P102.01X F102.01E

 8D report
Customer plant CK3 Internal claim # 0 Date of claim 7/19/2023
Customer contact Ivan Temix Nidec site 0 Date of D4-D8
Customer reference 0 Author Benito Sanchez Update of D4-D8

PLAN - DO (D4-D6)
Commitment date to present D4-D5-D6 (to be filled in with the quick response) : dd/mm/yy
D 4. Root cause of occurrence FTA 5 why's
Work out the root causes using FTA and 5 why's

Root cause of occurrence :

How was the defect reproduced ?

D 5. Root cause of non detection FTA 5 why's

Work out the root causes using FTA and 5 why's

Root cause of non detection :

D 6. Countermeasure occurrence and non detection

Actions Resp. Date plan. Date clos.

CHEK - ACT (D7-D8)

Commitment date to present D7-D8 (to be filled in with the check act) : dd/mm/yy
D 7. Effectiveness of action plan
Actions to check effectiveness (to plan with part D6) Resp. Date plan. Date clos.

D 8. Lessons learned
8.1 Do following documents require an update ? 8.2 Generalization of countermeasures to similar lines/ products
Resp. Date plan. Date clos.
PFMEA
Control Plan
Work instruction
Control instruction 8.3 Internal audit (if required)
Procedure Date Results
Control gage Comments
Maintenance instruction
Lesson Learned Card
Other
Other 8.4 Validation of 8D closure by client (if requested)
Other Name / Position Date

CLOSURE OF 8D BY NIDEC MANAGEMENT

Calculated cost of
Efficiency of 8D proven Nok stocks at zero Name Ivan Temix Date
incident
Validation by NIDEC management Decision Name Date

Management comments:

Ref. P102.01X F102.01E

 Lesson Learned Card
Customer plant Nidec Site Detection Logistics
Internal claim # Author LLC Type Occurrence Process
Date of incident Date of LLC Management Product

1. WHAT WAS THE PROBLEM? (5W + 2H) 2. WHAT IS THE CAUSE?

What happened ?
Paros maquina pieza se atora.
Why it is a problem ?
Genera micro paros y baja la produccion.
When did it happen ?
45126
Who has detected it ?
Línea de producción CK3-L1
Where has been detected ?
CW010
How has it been detected ?
Area de Stator
How many ?
0

3. DESCRIPTION OF THE APPLIED MODIFICATION

BEFORE AFTER

4) WHAT WE LEARNED?
ERADICATION CHECKING
SIGNALING
What is the countermeasure that was put in place to avoid What is the countermeasure supposed to do or make or hightlight
What is the method (who, what, how) for the countermeasures?
recurrence ? when detecting a non conformity ?

5. WHAT HAS BEEN MODIFIED ?

d. Control Plan and PFMEA
b. All documents have been

e. Maintenance instructions
validated with the operators

describe what they must do

checklists, reaction sheets,
preventive maintenance...)
according to Before/ After

j. Operators can correctly

g. Visual aids are posted
c. Procedures and work

h. Operators and other

updated and has been
a. Proces is modified

avalaible (records,5 '

functions are trained

i. Proof of training is
f. Records (start-up
instructions

meeting)

k. Other:

l. Other:
sheet

6. POTENTIAL APPLICABILITY
Product :
Line / process :
Share LLC with other sites :
Nidec approval (if required):

Quality Manager Site Director R&D Director Purchasing Director Productline Director Operations Director

Ref. P102.01X F102.01E