Revision History

Approved: David Cue

Approved: Craig Rigby

Signature/Date

Signature/Date

10/10/2007

10/10/2007

Released: Joyce Kaiser

Signature/Date
10/10/2007

Revision Level
01
02

HV-LOS-FR-14-01, Rev. 02 (10-Oct.-07)

Revision Date
26-Oct-05
10-Oct-07

Description of Changes
Initial release
Revised for the Joint Venture

Johnson Controls - Saft

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Instructions for the 8D Problem Analysis Report

(*) Mandatory information
HEADER
1) Customer: (e.g., Daimler-Chrysler, VW, BMW, AIRBUS, ASTRIUM, etc.)
2) Program: (e.g., HV-ISG, CONVERTEAM, INTENSIUM, etc.)
3) Product: (e.g., Battery System name, traceability number, etc.)
4) Issue #: JCS issue tracking # (May also include Customer or Supplier tracking #)
5) Date Issue Occurred: Open date for the issue
6) 4D Due Date: Default is 48 hours from date issue occurred
7) 8D Due Date: If applicable. Default is 1 week from date issue occurred
8) Date Issue Closed: All permanent corrective actions have been implemented and their effectiveness validated; All required
support documents have been submitted.
TEAM MEMBERS
1) Champion Name/Title/Phone Number/Email Address: Contact information for the individual who is leading the corrective action
and submitting the 4D/8D.
Problem Champion: Technical Engineer, Process Engineer, Production Engineer who is in charge of the component, process,
production area where the problem takes place
Quality Champion: Quality Engineer who is associated with the Problem Champion and is in charge of following up the action
plan documentation and implementation.
2) Additional Team Member Name(s)/Title(s)/Phone Number(s)/Email Address(es): Contact information for the cross-functional
team members who share responsibility for the corrective actions.
PROBLEM DESCRIPTION
1) Description: Describe the issue from a customers perspective; what would they know?
When: When were the parts manufactured? When were they assembled? When were the assemblies shipped to the
customer? When assembled in the application? When shipped from OEM?
Detection: How was JCS made aware of the issue? Who provided the information?
Extent: How many units are suspected? Proportion found suspect. Where has the data come from - in house, in transit, at
customer.
Failure Mode: How does the issue manifest itself?
2) Impact on Customer: Identify the potential for shut down, line interruptions, yard recalls, warranty. etc.
3) Facilities Involved: Customer, JCS and any Suppliers
INTERIM CONTAINMENT
1) What actions were taken to immediately protect the customer and contain any suspect inventory? Since original notification,
how are we containing this issue? What is the current containment status? What sorting have we done, where and how have
we verified its effectiveness? If a rework or retrofit plan has commenced what is it and how have we verified effectiveness
attach plan with sketches and trend graphs.
2) Other Product/Platform at Risk: Other JCS lines or Customers who may be impacted by this issue
3) Identification of Certified Material: Color, size, location, and content of label or hand-written identification on each part and/or
container of certified material.
4) Sorting Results: Time, date, total number sorted and quantity rejected - broken down by facility (e.g., Customer, JCS, Supplier)
5) Sorted #: Total # sorted at all facilities
6) Defect #: Total # of defects found at all facilities
7) Interim Containment Start Date: Date
ROOT CAUSE
Note: The form provides fields for documentation of a single root cause. If additional root causes are identified, "Copy" rows 2731 and "Insert Cut Cells" to create additional fields.
1) Why Made & How Verified: Identify each root cause for why the issue occurred. Has it been turned on and off? How? Verifiy
through statical evidence/hypothesis testing. If not verified by turning on/off, identify as a suspected root cause.
Variation: What are opportunities for variation in the process, i.e. how many fixtures do the same process? How many weld
cells or robots? Etc.
2) Why Shipped & How Verified: Identify each root cause for why the issue escaped. Has it been turned on and off? How? Verifiy
through statical evidence/hypothesis testing. If not verified by turning on/off, identify as a suspected root cause.
PERMANENT CORRECTIVE ACTION
Note: The form provides fields for documentation of a single root cause verification. If additional root causes have been
identified, "Copy" rows 32-40 (steps1-5) and "Insert Cut Cells" to create additional fields.
1) Corrective Action for Why Made: Identify permanent corrective action(s) planned to address the root cause.
2) Corrective Action for Why Shipped: Identify permanent corrective action(s) planned to address the root cause.

HV-LOS-FR-14-01, Rev. 02 (10-Oct-07)

Johnson Controls - Saft

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Instructions for the 8D Problem Analysis Report

VERIFICATON OF CORRECTIVE ACTIONS
1) Has the issue been turned on and off? How? Verification through statical evidence / hypothesis testing. Verification of corrective
action for each why made and why shipped is required.
2) Corrective Action Owner Name/Phone Number/Email Address: Contact information for the individual responsible for
implementing the corrective action.
3) Target Completion Date: Date by which all of the corrective actions for this root cause will be implemented.
4) Build Date for Certified Material: "Clean point" at which all material is certified as good.
5) How Will New Parts Be Identified? Color, size, location, and content of label or hand-written identification on each part and/or
container of certified material.
PREVENTION
1) How will this issue be avoided in the future? Identify systematic changes that will be put in place to prevent the issue from
occurring again. If applicable, standardize the improvements in other "at risk" areas.
2) Other Facilities or Platforms At Risk? Identify name, part#, corrective action owner for follow up & due date for any other facility
or platform that may be at risk for the same issue. Enter "N/A" if the issue is isolated. "Copy" rows 48-49 and "Insert Cut Cells"
to create additional fields as necessary.
3) Has the necessary documentation been updated? Identify the documents that must be updated to include the permanent
corrective actions, along with who is responsible for the updates and the dates by which they will be updated. Enter "N/A" if the
document does not have to be udpated.
CLOSURE
1) Closure Statement: Close issue (Begin with words noted in followed by the rationale for closure.)

HV-LOS-FR-14-01, Rev. 02 (10-Oct-07)

Johnson Controls - Saft

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8D Problem Analysis Report

Report Date (*):

Report Revision Level (*):

Customer (*):

Date Issue Occurred (*):

Program (*):

4D Due Date:

Product (*):

8D Due Date:

Issue #:

Date Issue Closed:

RMA #:

Link to PDCA Phase:

Issue Frequency:

1. Team Members

2. Problem Description

New

Reccurent

Other 8D Report:

Report Reference:

Prototype Development
Pre-Launch
Launch/Production
P

No

Yes

Reference other 8D report:

Problem Champion Name (*)

Problem Champion Title

Problem Champion Phone Number

Problem Champion E-mail Address

Quality Champion Name (*)

Quality ChampionTitle

Quality Champion Phone Number

Quality Champion E-mail Address

Additional Team Member Name(s) (*)

Title(s)

Phone Number(s)

E-mail Address(es)

Description (Describe issue in terms of what, where, when and how many) (*)

Impact on Product & Application (Identify the potential for safety, fit, function like performance, etc.)

Safety Fit, Function

Appearence

Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc.)

Quality Of Manufacturing or Assembling

Facilities Involved (Customer, JCS and any Suppliers)

3. Interim Containment

What actions were taken to immediately protect the customer and contain any suspect inventory?

Other Product/Platforms at Risk ?

No

Yes

Identification of certified material ?

Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)

Sorted #
4. Root Cause(s)

ROOT CAUSE(S) (*)

Why Made & How Verified
Cause #

Defect #

No

No

Yes

Yes

Interim Containment Start Date

Identification in progress
Identification Not Completed
Identification Completed

Cause #

Cause #

Why Shipped & How Verified

5. Permanent Corrective
Action(s)

CORRECTIVE ACTION(S) FOR ROOT CAUSE(S) (*)

Corrective Action for Why Made #
for Cause #

Corrective Action for Why Made #

for Cause #

Corrective Action for Why Made #

for Cause #

Corrective Action for Why Shipped

HV-LOS-FR-14-01, Rev. 02 (10-Oct-07)

Johnson Controls - Saft

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Report Date (*):

6. Verification of
Corrective Action(s)

7. Prevention

Report Revision Level (*):

Corrrective Action Owner Name

C.A. Owner Phone Number

Build Date for Certified Material

How Will New Parts Be Identified?

Has the necessary documentation been

updated? (*)

HV-LOS-FR-14-01, Rev. 02 (10-Oct-07)

C.A. Owner E-mail Address

Target Completion Date

Part Number

C.A. Owner for Follow Up

Due Date

Affected Document
DFMEA
PFMEA
Control Plan
Process Flow
Operation Instructions
Drawing
Technical Specification

Owner for Update

Date

How will this issue be avoided in the future?

Other Facilities or Platforms At Risk

Name

8. Closure

Report Reference:

Verification of Corrective Action(s): Has the issue been turned on and off? How? Verification through statical evidence / hypothesis testing. Verification of corrective
action for each why made and why shipped is required.

Closure Statement

No

Yes

No Yes
No Yes
No Yes
No Yes
No Yes
No Yes
No Yes
Documentation
Updated or N/A
Root causes identified
Corrective actions completed
Corrective Actions Efficiency
Verified

Johnson Controls - Saft

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