Safety Checklist

US InstructionsInstructions for the 8D Problem Analysis ReportHEADER1)Customer: (e.g., Daimler-Chrysler)2)Program: (e.g., LH)3)Product: (e.g., Overhead System)4)Issue #: JCI issue tracking # (May also include Customer or Supplier tracking #)5)Date Issue Occurred: Open date for the issue6)4D Due Date: Default is 24 hours from date issue occurred7)8D Due Date: If applicable. Default is 1 week from date issue occurred8)Date Issue Closed: All permanent corrective actions have been implemented and their effectiveness validated; All required support documents have been submitted.Discipline 1Discipline 1. TEAM MEMBERS1)Champion Name/Title/Phone Number/Email Address: Contact information for the individual who is leading the corrective action and submitting the 4D/8D.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.Discipline 2. PROBLEM DESCRIPTION1)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 vehicles? When shipped from OEM?Detection: How was AG 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, JCI and any SuppliersDiscipline 3. INTERIM CONTAINMENT1)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 JCI lines or Customers who may be impacted by this issue3)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, JCI, Supplier)5)Interim Containment Start Date: DateDiscipline 4. ROOT CAUSENote: The form provides fields for documentation of a single root cause. If additional root causes are identified, "Copy" rows 27-31 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.Discipline 5. PERMANENT CORRECTIVE ACTIONNote: 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.Discipline 6. VERIFICATON OF CORRECTIVE ACTIONS1)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.Discipline 7. PREVENTION1)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)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.Discipline 8. CLOSURE1)Closure Statement: Close issue (Begin with words noted in followed by the rationale for closure.)VERSION OF DOCUMENT1)Version 1.5: Formatting text fields imposed.2)Version 1.6: IRIS R.11.1 enhancements update.

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US Example8D Problem Analysis ReportTemplate Version 11.4Customer:JCI MurfreesboroDate Issue Occurred:3/31/11Program:Nissan X-61B4D Due Date:4/1/11Product:R/H Mounting Bracket assembly - Seating System8D Due Date:4/8/11Issue #:SMRR - #1111982 (Supplier #4057)Date Issue Closed:6/11/11For 4D requests, suppliers must, at a minimum, complete the highlighted fields in yellow. (See the Instructions tab for further details). Areas requiring numeric values such as dates and phone numbers must be in a numeric format.1. Team MembersChampion NameChampion TitleChampion Phone NumberChampion E-mail AddressLarry DoePlant Manager(555) 555-5555Larry.DoeASupplier.comAdditional Team Member Name(s)Title(s)Phone Number(s)E-mail Address(es)Jim DoeQuality Manager(555) 555-5555Jim. Doe@Supplier.comJane DoeProduction Manager(555) 555-5555Jane.Doe@Supplier.comSteve DoeMaintenance Technician(555) 555-5555Steve.Doe@Supplier.com2. Problem DescriptionDescription (Describe issue in terms of what, where, when and how many)On Friday, 4/1/11, (Supplier) received an email notification from (JCI Murfreesboro) regarding missing striker pins on part number 1298712 Rev. 06 Mounting Bracket assembly-Lot #276. This lot of components (2,234 pcs.) were built into assemblies at JCI Murfreesboro 3/30/11, first shift being shipped only to the Nissan Smyrna plant 3/30/11 second shift. Five (5) suspect parts were identified on complete seat assemblies at Nissan Smyrna during first shift 3/31/11. JCI Customer liaison notified immediately and subsequently notification was made to the JCI Murfreesboro facility. It was noted that seats would not latch properly.Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..)JCI Murfreesboro reported their Customer (Nissan) had (5) seats that had to be swapped out due to missing striker pins causing seat to not latch properly. 100% sort was implemented at JCI Murfreesboro. Yard campaign initiated to validate vehicles located at the Nissan Smyrna facility.Facilities Involved (Customer, JCI and any Suppliers)Nissan Smyrna, JCI Murfreesboro, Supplier3. Interim ContainmentWhat actions were taken to immediately protect the customer and contain any suspect inventory?1. No WIP Material currently in-house at Customer location (JCI Murfreesboro) - Verified 4/1/11 John Doe - Quality ManagerMaterial identified at Supplier location:2. (1746) parts contained and isolated with striker rod - Verified 4/1/11 John Doe - Quality Manager (1904) parts contained and isolated with striker rod and pin weld - Verified 4/1/11 John Doe - Quality Manager (905) completed weld and paint contained and isolated - Verified 4/1/11 John Doe - Quality Manager3. (1,680) parts shipped to JCI on 3/28/11 - Verified John Doe - Quality Manager (1,680) parts shipped to JCI 4/5/11 - Verified 4/6/11 Jim Doe - Production Supervisor4. JCI currently has 3rd party validating wire presence - Reported to John Doe - Quality Manager - 4/1/115. (Supplier) contacted on 4/5/11 @ 11:20am by Murfreesboro informing of containment sort at Nissan Smyrna by 3rd party - Reported to John Doe - Quality Manager6. On 4/6/11 @ 10:35 am (Supplier) received an email from JCI Murfreesboro with attached sort instructions directing (Supplier) to check parts using a screwdriver to apply pressure against striker rod for certification process.Other Product/Platform at Risk ?Identification of certified material ?This specific assembly is not used on any other platform. No other product of a similar geometry is produced by Supplier.Conforming assemblies to be identified with a 'Green' dot on the right side of the lower bracket (See attached photographs). Certified material will have 8.5 x 11.0 certified placards on the container (See attached example). No material will be shipped until certification method has been validated as effective and agreement is secured from receiving Customer plant.Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)1. All parts are currently on hold, shipment of (1,680) pcs on 4/5/11 - 5pm, were sorted and certified per visual rod presence verification as agreed upon with JCI quality representatives on 4/1/11. (0) fallout noted based on this criteria.2. All suspect material contained in house (4,555 pcs.) will be scrapped to avoid escape point and mitigate any potential risk to Customer3. (400) vehicles reviewed at Nissan 4/1/11 - Second shift. (0) fallout reported.Interim Containment Start Date4/5/11For 8D requests, suppliers must, at a minimum, complete the fields highlighted in green. (See the Instructions tab for details) Areas requiring numeric values, such as dates or phone numbers, must be in a numeric format.4. Root CauseROOT CAUSE #1Why Made & How Verified1. Assembly produced that exhibited insufficient welding of Striker Pin to lower bracket.

Why?Resistance welding operation did not sufficiently fuse Retaining pin to lower bracketWhy?Welding pressure was not properly set/controlled to allow for proper fusing of detailsWhy?Several products are produced through this welder. Each with their own individual required parameters (Pneumatic weld pressure being one of those). These are set manually during process set-up, and are not monitored with direct feedback to the machine controller during production operation. It appears during this specific run this was not set properly, or had been changed from the original set up.Why?Equipment did not have sufficient controls installed to ensure this failure mode (insufficient welding of striker pin to bracket) would not occur.

How Verified:A study was performed varying the weld pressure during sequential cycles of the weld operation. It was determined that as weld pressure increased this had a negative affect on Proof load values. This progressed to a point where the Striker pin would not meet the (500N) minimum requirement as noted on the print.Why Shipped & How Verified1. An assembly was shipped to Customer that exhibited insufficient welding of Striker Pin to lower bracket

Why?Assembly with an insufficient weld was not detected during current inspection processWhy?Weld retention only verified on an audit basis during the production runWhy?Weld retention noted as an attribute verification per Control Plan on design record (Drawing no. 1298712 Rev. 6). Manufacturing system was not designed to verify 100% proof load conformance.Why?It was not identified as a specific requirement.

How Verified:Audit frequency ((2) parts per shift) was reviewed and determined it would not be sufficient to ensure no escape of this specific non-conformance.ROOT CAUSE #2Why Made & How VerifiedWhy Shipped & How Verified5. Permanent Corrective ActionROOT CAUSE #1Corrective Action for Why Made1a. Air pressure regulator fabricated to lock out manual air pressure setting.1b. Inspection implemented after change over to validate proper parameter setting on job running.1c. Logic and controls upgrade to be performed on existing welder to allow for real time air pressure monitoring and lock out if air parameters are exceeded high or low, requiring a reset by supervision only trough a biometric control.1d. Read across to all existing ped welders within L&W Plant 2 for logic upgrade so same controls can be implemented throughout plant per time line.1e. Update all appropriate APQP documents to reflect this specific failure mode and noted counter measures.Corrective Action for Why Shipped1a. Addition of 100% Proof load verification of Retaining Pin during locating pin installation1b. Update all appropriate In-process/ODS documentation as it relates to this specific failure mode.ROOT CAUSE #2Corrective Action for Why MadeCorrective Action for Why Shipped6. Verification of Corrective Action(s)Verification of Corrective Action: Has the issue been turned on and off? How? Verification through statistical evidence / hypothesis testing. Verification of corrective action for each why made and why shipped is required.Why Made?After implementation of above referenced corrective actions studies were performed on 4/8/11 with regards to proof load requirements. It was determined that once parameters were set, and the system monitored for conformance to these settings (see attached set-up sheet), proof load performance was statistically capable to the noted tolerance on the engineering drawing. As settings were deviated from this window, proof load performance diminished as expected. (See attached studies)

Why Shipped?100% proof load verification is effective. A sample of (10) parts that had passed on-line verification were taken and destructively tested (See attached results). Results confirm assemblies are conforming. (10) Parts that were purposely not welded were detected on-line and equipment locked as programmed.Corrective Action Owner NameC.A. Owner Phone NumberC.A. Owner E-mail AddressTarget Completion DateJohn Doe(555) 555-5555John.Doe@Supplier.com5/15/11Build Date for Certified MaterialHow Will New Parts Be Identified?4/9/11Production certified material to be identified with an 'Orange' shipping label.7. PreventionHow will this issue be avoided in the future?1. For this specific failure mode, system to be part of on-going layered process audits to ensure manufacturing parameters and assembly performance (proof load) are maintained.2. Information from 'read across' exercise to be summarized and reviewed. Applicable improvements to be implemented and documented on other similar manufacturing processes.Has the necessary documentation been updated?Affected DocumentOwner for UpdateDateDFMEANot requiredPFMEAJohn Doe4/11/11Control PlanJohn Doe4/11/11Process FlowJim Doe4/11/11Operation InstructionsJohn Doe4/11/11DrawingNot requiredDesign StandardsNot required8. ClosureClosure Statement (Validation)Close issue based on (5) subsequent production runs (10,564 pcs.) that have been produced with (0) fallout for proof load requirement. Customer has reported (0) issues since receiving certified production material. As of 6/11/11, Corrective actions have been deemed effective.

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US PAR - 8D Form8D Problem Analysis ReportTemplate Version 11.4Customer:JCA SEATING (M) SDN BHDDate Issue Occurred:Program:GAJC SHIPMENT PARTS4D Due Date:Product:REFER TO INVOICE: MALAY 1405208D Due Date:Issue #:Date Issue Closed:For 4D requests, suppliers must, at a minimum, complete the highlighted fields in yellow. (See the Instructions tab for further details). Areas requiring numeric values such as dates and phone numbers must be in a numeric format.1. Team MembersChampion NameChampion TitleChampion Phone NumberChampion E-mail AddressAdditional Team Member Name(s)Title(s)Phone Number(s)E-mail Address(es)GAJCSUPPLIER+86 (20)2093 7542Yangtao.Wen@jci.comYANGTAO WEN2. Problem DescriptionDescription (Describe issue in terms of what, where, when and how many)Refer to the photos, there are a lot of space in the container. Therefore, at time, it is unavoidable that the port transfering the cargo from the port to the ship or vise versa or movement in the sea might cause the cargo to be tilted.Stuffing is done by the shipper and they will sealed the container. Therefore, besides shipper, no one can actually see the cargo in the container. It would be advisable if shipper could latch the cargo on moving instead or reinforce their cargo in plastic pallets or wooden pallets.Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..)Facilities Involved (Customer, JCI and any Suppliers)3. Interim ContainmentWhat actions were taken to immediately protect the customer and contain any suspect inventory?Stuffing is done by the shipper and they will sealed the container. Therefore, besides shipper, no one can actually see the cargo in the container. It would be advisable if shipper could latch the cargo on moving instead or reinforce their cargo in plastic pallets or wooden pallets.Other Product/Platform at Risk ?Identification of certified material ?Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)Interim Containment Start Date MM/DD/YYYYFor 8D requests, suppliers must, at a minimum, complete the fields highlighted in green. (See the Instructions tab for details) Areas requiring numeric values, such as dates or phone numbers, must be in a numeric format.4. Root CauseROOT CAUSE #1Why Made & How VerifiedWhy Shipped & How VerifiedROOT CAUSE #2Why Made & How VerifiedWhy Shipped & How Verified5. Permanent Corrective ActionROOT CAUSE #1Corrective Action for Why MadeCorrective Action for Why ShippedROOT CAUSE #2Corrective Action for Why MadeCorrective Action for Why Shipped6. Verification of Corrective Action(s)Verification of Corrective Action: Has the issue been turned on and off? How? Verification through statistical evidence / hypothesis testing. Verification of corrective action for each why made and why shipped is required.Corrective Action Owner NameC.A. Owner Phone NumberC.A. Owner E-mail AddressTarget Completion Date MM/DD/YYYYBuild Date for Certified Material MM/DD/YYYYHow Will New Parts Be Identified?7. PreventionHow will this issue be avoided in the future?Has the necessary documentation been updated?Affected DocumentOwner for UpdateDate MM/DD/YYYYDFMEAPFMEAControl PlanProcess FlowOperation InstructionsDrawingDesign Standards8. ClosureClosure Statement (Validation)

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US RMA&Acct #Please submit your RMA / Account #'s in the cells below if you are having material debited / returned to you:RMA:RMA #Account #'s:UPS #FEDEX #DHL #Airbourne ##(Specify Company)OtherSupplier Disposition:ScrapReturnNone(Check the box)Address for Return:Name(If the Return box isStreetchecked above)CityStateZipAttention To:Name

German -AnweisungenAnweisungen fr den Analysebericht zu 8D-ProblemenKOPFZEILE1)Kunde: (z. B. Daimler-Chrysler)2)Programm: (z.B. LH)3)Produkt: (z.B. Dachhimmelsystem)4)Problem-Nr.: JCI-Problemverfolgungs-Nr. (Enthlt evtl. auch Kunden- oder Lieferanten-Verfolgungs-Nr.)5)Datum, an dem das Problem aufgetreten ist: Erffnungsdatum fr das Problem6)4D-Flligkeitsdatum: Der Standardwert betrgt 24 Stunden, gerechnet ab dem Datum, an dem das Problem aufgetreten ist.7)8D-Flligkeitsdatum: Wenn zutreffend. Der Standardwert betrgt 1 Woche, gerechnet ab dem Datum, an dem das Problem aufgetreten ist.8)Datum, an dem das Problem geschlossen wurde: Alle permanenten Korrekturmanahmen wurden eingefhrt und deren Wirksamkeit berprft. Alle erforderlichen untersttzenden Dokumente wurden eingereicht.TEAMMITGLIEDER1)Champion-Name/Titel/Telefonnummer/E-Mail-Adresse: Kontaktinformationen fr die Person, die die Korrekturmanahme leitet und den 4D/8D einreicht.2)Weitere Namen von Teammitgliedern/Titel/Telefonnummer(n)/E-Mail-Adresse(n): Kontaktinformationen fr die bereichsbergreifenden Teammitglieder, die gemeinsam fr die Korrekturmanahmen zustndig sind.PROBLEMBESCHREIBUNG1)Beschreibung: Erlutern Sie das Problem aus der Sicht eines Kunden. Was wei er darber?Wann: Wann wurden die Artikel hergestellt? Wann wurden sie montiert? Wann wurden die montierten Einheiten an den Kunden geliefert? Wann wurden sie in den Fahrzeugen eingebaut? Wann wurden sie vom Originalhersteller (OEM) versandt?Erkennung: Wie wurde der AG das Problem mitgeteilt? Wer hat die Informationen bereitgestellt?Ausma: Wie viele Einheiten sind zweifelhaft? Proportion wird angezweifelt. Woher stammen die Daten - werksintern, Transportweg, beim Kunden.Fehlermodus: Wie manifestiert sich das Problem?2)Auswirkung auf den Kunden: Identifizieren Sie das Potenzial fr Ausfallzeiten, Unterbrechungen der Fertigungsstrae, Stapelplatzrckrufe, Garantieleistungen usw.3)Beteiligte Einrichtungen: Kunde, JCI und alle LieferantenVORLUFIGE RCKHALTUNG1)Welche Manahmen wurden ergriffen, um den umgehenden Schutz des Kunden und die Rckhaltung aller verdchtigen Inventarobjekte zu gewhrleisten? Wie grenzen wir seit der ursprnglichen Benachrichtigung dieses Problem ein? Wie lautet der aktuelle Zurckhaltungsstatus? Welche Sortierungen haben wir durchgefhrt, wo und wie haben wir deren Wirkamkeit verifiziert? Wenn ein Nacharbeits- oder Nachrstplan in Kraft gesetzt wurde worum handelt es sich und wie haben wir die Wirksamkeit berprft fgen Sie den Plan mit Zeichnungen und Trenddiagrammen bei.2)Weitere gefhrdete Produkte/Plattformen: Andere JCI-Fertigungsstraen oder Kunden, die von diesem Problem betroffen sein knnen3)Identifizierung von zertifiziertem Material: Farbe, Gre, Ort und Inhalt des Etiketts oder handschriftliche Identifikation an den einzelnen Artikeln und/oder Transportverpackungen des zertifizierten Materials.4)Ergebnisse der Sortierung: Uhrzeit, Datum, Gesamtzahl der Sortierungen und zurckgewiesenen Stckzahl - aufgegliedert nach Einrichtung (z.B. Kunde, JCI, Lieferant)5)Startdatum fr die vorlufige Rckhaltung: DatumHAUPTURSACHE DER FEHLERENTSTEHUNGHinweis: Das Formular enthlt Felder zur Dokumentation einer Hauptursache fr die Fehlerentstehung. Wenn weitere Hauptursachen der Fehlerentstehung (Root Causes) identifiziert werden, kopieren Sie die Zeilen 27 31 und fgen sie ein, um zustzliche Felder zu erstellen.1)Warum vorgenommen und wie verifiziert: Identifizieren Sie die einzelnen Hauptursachen der Fehlerentstehung, warum das Problem aufgetreten ist. Wurde es ein- und ausgeschaltet? Wie? Verifizieren Sie dies durch statische Nachweise/Hypothesetests. Ist die Verifizierung durch Ein-/Ausschalten nicht mglich, identifizieren Sie es als eine vermutete Ursache.Variation: Wie lauten die "Opportunities" (Gelegenheiten) fr Variationen im Prozess, d.h. wie viele Vorrichtungen fhren denselben Prozess durch? Wie viele Schweizellen oder Roboter? usw.2)Warum geliefert und wie verifiziert: Identifizieren Sie die einzelnen Hauptursachen, warum das Problem verschwunden ist. Wurde es ein- und ausgeschaltet? Wie? Verifizieren Sie dies durch statische Nachweise/Hypothesetests. Ist die Verifizierung durch Ein-/Ausschalten nicht mglich, identifizieren Sie es als eine vermutete Ursache.DAUERHAFTE KORREKTURMANAHMEHinweis: Das Formular enthlt Felder fr die Dokumentation der Verifizierung einer Hauptursache fr die Fehlerentstehung. Wenn weitere Hauptursachen (Root Causes) identifiziert wurden, kopieren Sie die Zeilen 32 40 (Schritte 1 5) und fgen sie ein, um zustzliche Felder zu erstellen.1)Korrekturmanahmen fr "Warum vorgenommen": Identifizieren Sie permanente Korrekturmanahmen, die zum Angehen der Hauptursache geplant wurden.2)Korrekturmanahmen fr "Warum geliefert": Identifizieren Sie permanente Korrekturmanahmen, die zum Angehen der Hauptursache geplant wurden.VERIFIZIERUNG DER KORREKTURMANAHMEN1)Wurde das Problem ein- und ausgeschaltet? Wie? Verifizierung durch statische Nachweise/Hypothesetests. Verifizierung der Korrekturmanahmen fr jedes "Warum vorgenommen" und "Warum geliefert" ist erforderlich.2)Name des Verantwortlichen fr die Korrekturmanahme/Telefonnummer/E-Mail-Adresse: Kontaktinformationen fr die Person, die fr die Implementierung der Korrekturmanahme verantwortlich ist.3)Angestrebtes Abschlussdatum: Datum, an dem alle Korrekturmanahmen fr diese Hauptursache implementiert sind.4)Aufbaudatum fr zertifiziertes Material: "Bereinigungspunkt", an dem alle Materialien fr "in Ordnung" befunden wurden.5)Wie werden neue Teile identifiziert? Farbe, Gre, Ort und Inhalt des Etiketts oder handschriftliche Identifikation an den einzelnen Artikeln und/oder Transportverpackungen des zertifizierten Materials.PRVENTION1)Wie wird dieses Problem in Zukunft verhindert? Identifizieren Sie systematische zu implementierende nderungen, damit das Problem nicht wieder auftritt. Wenn zutreffend, standardisieren Sie die Verbesserungen in anderen gefhrdeten Bereichen.2)Wurde die erforderliche Dokumentation aktualisiert? Geben Sie die Dokumente an, die bezglich folgender Punkte aktualisiert werden mssen: permanente Korrekturmanahmen, Verantwortlicher fr die Aktualisierungen sowie Termine, bis zu denen sie aktualisiert sein werden. Geben Sie "N/A" (nicht zutreffend) ein, wenn das Dokument nicht aktualisiert werden muss.ABSCHLUSS1)Abschlusserklrung: "Abschlieen von Problem " (Beginnen Sie mit den Worten in den Anfhrungszeichen, gefolgt von der Begrndung fr den Abschluss.)VERSION DES DOKUMENTES1)Version 1.5: Formatierung der Textfelder verbessert.2)Version 1.6: IRIS R.11.1 enhancements update.

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German PAR - 8D-FormularAnalysebericht zu 8D-ProblemenKunde:Datum, an dem das Problem aufgetreten ist:Programm:4D-Flligkeitsdatum:Produkt:8D-Flligkeitsdatum:Problem-Nr.:Datum, an dem das Problem geschlossen wurde:Vom Lieferanten sind die gelb hervorgehobenen Formularbereiche fr den 4D auszufllen. (Siehe auch die vorstehende Registerkarte 'Anweisungen' fr weitere Informationen). Zellen, die numerische Werte wie Datumsangaben oder Telefonnummern enthalten sollen, mssen Zahlenangaben enthalten.1. TeammitgliederChampion-NameChampion-TitelChampion-TelefonnummerChampion-E-Mail-AdresseNamen von weiteren TeammitgliedernTitelTelefonnummer(n)E-Mail-Adresse(n)2. ProblembeschreibungBeschreibung (Erlutern Sie das Problem, indem Sie folgende Fragen stellen: "Was?", "Wo?", "Wann?" und "Wie viele?".)Auswirkung auf den Kunden (Identifizieren Sie das Potenzial fr Ausfallzeiten, Unterbrechungen der Fertigungsstrae,Stapelplatzrckrufe, Garantieleistungen usw.)Beteiligte Einrichtungen (Kunde, JCI und Lieferanten)3. Vorlufige RckhaltungWelche Manahmen wurden ergriffen, um den umgehenden Schutz des Kunden und die Rckhaltung aller verdchtigen Inventarobjekte zu gewhrleisten?Weitere gefhrdete Produkte/Plattformen?Identifizierung von zertifiziertem Material?Ergebnisse der Sortierung (Uhrzeit, Datum, Gesamtzahl der Sortierungen und zurckgewiesene Menge)Startdatum fr die vorlufige Rckhaltung DD.MM.YYYYVom Lieferanten sind die grn hervorgehobenen Formularbereiche fr den 8D auszufllen. (Siehe auch die vorstehende Registerkarte 'Anweisungen'). Zellen, die numerische Werte wie Datumsangaben oder Telefonnummern enthalten sollen, mssen Zahlenangaben enthalten.4. HauptursacheHAUPTURSACHE NR. 1Warum vorgenommen und wie verifiziertWarum geliefert und wie verifiziertHAUPTURSACHE NR. 2Warum vorgenommen und wie verifiziertWarum geliefert und wie verifiziert5. Permanente KorrekturmanahmenHAUPTURSACHE NR. 1Korrekturmanahmen fr "Warum vorgenommen"Korrekturmanahmen fr "Warum geliefert"HAUPTURSACHE NR. 2Korrekturmanahmen fr "Warum vorgenommen"Korrekturmanahmen fr "Warum geliefert"6. Verifizierung der KorrekturmanahmenVerifizierung der Korrekturmanahmen: Wurde das Problem ein- und ausgeschaltet? Wie? Verifizierung durch statische Nachweise/Hypothesetests. Verifizierung der Korrekturmanahmen fr jedes "Warum vorgenommen" und "Warum geliefert" ist erforderlich.Name d.Verantw. f.d. Korrekturm.Telefon-Nr. des Verantw. f.d.KME-Mail-Adresse d.Verantw. f.d.KMAngestrebtes Abschlussdatum DD.MM.YYYYAufbaudatum fr zertif. Material DD.MM.YYYYWie werden neue Teile identifiziert?7. PrventionWie wird dieses Problem in Zukunft verhindert?Wurde die erforderliche Dokumentation aktualisiert?Betroffenes DokumentVerantw. fr die AktualisierungDatum DD.MM.YYYYDFMEAPFMEAKontrollplanProzessflussBetriebsanweisungenZeichnungDesignstandards8. AbschlussAbschlusserklrung

French InstructionsInstructions relatives au rapport d'analyse des problmes 8DEN-TETE1)Client : (par ex., Daimler-Chrysler)2)Programme : (par ex., LH)3)Produit : (par ex., systme de pavillon)4)N problme : n de suivi du problme JCI (peut comprendre un n de suivi du client ou du fournisseur)5)Date d'apparition du problme : date d'ouverture du problme6)Date de remise du 4D : la valeur par dfaut est de 24 heures compter de la date d'apparition du problme7)Date de remise du 8D : le cas chant. La valeur par dfaut est de 1 semaine compter de la date d'apparition du problme8)Date de clture du problme : toutes les actions correctives permanentes ont t mises en uvre et leur efficacit a t valide ; tous les documents justificatifs requis ont t prsents.MEMBRES D'EQUIPE1)Nom/Fonction/Numro tl./adresse e-mail du Champion : informations relatives la personne qui est responsable de l'action corrective et qui soumet le 4D/8D.2)Nom/Fonction/Numro de tl./adresse e-mail des autres membres d'quipe : informations relatives aux membres de l'quipe pluridisciplinaire qui partagent la responsabilit des actions correctives.DESCRIPTION DU PROBLEME1)Description : dcrire le problme sous l'angle du client ; qu'est-ce qu'il en saurait ?Quand : Quand les pices ont-elles t produites ? Quand ont-elles t assembles ? Quand les ensembles ont-ils t expdis au client ? Quand ont-il t monts dans les vhicules ? Quand ont-ils t expdis par l'OEM ?Dtection : Comment l'AG a-t-il dcouvert le problme ? Qui a fourni les informations correspondantes ?Etendue : Combien d'units sont suspectes ? Proportion dtermine comme suspecte. D'o proviennent les donnes - en interne, pendant le transport, chez le client.Mode de dfaillance : Comment le problme se manifeste-t-il ?2)Impact sur le client : identifier le risque d'arrt de la production, d'interruptions sur la chane, de rappel de produits, de garantie, etc.3)Sites concerns : client, JCI et fournisseursCONTAINMENT PROVISOIRE1)Quels mesures ont t prises afin de protger immdiatement le client et d'isoler tout stock suspect ? Depuis la notification initiale, comment matrisons-nous le problme? Quel est le statut de containment actuel ? Quel tri avons-nous ralis, o et comment avons-nous vrifi l'efficacit de ce tri ? Si un plan de rusinage et de retouche a dbut en quoi consiste-t-il et comment avons-nous vrifi son efficacit joindre le plan avec les croquis et les graphiques de tendance.2)Risque pour quel autre produit/plateforme : autres chanes JCI ou clients qui pourraient subir les consquences du problme3)Identification des produits certifis : couleur, taille, emplacement, et contenu de l'tiquette ou de l'identification manuscrite sur chaque pice et/ou container de produits certifis.4)Rsultats du tri : heure, date, nombre total de produits tris et quantit refuse - donnes ventiles par site (par ex., client, JCI, fournisseur)5)Date de dbut du containment provisoire : dateCAUSE PREMIERERemarque : le formulaire contient des champs permettant de dcrire une seule cause premire. Si d'autres causes premires sont identifies, "copier" les lignes 27-31 et "coller" les cellules correspondantes afin de crer des champs supplmentaires.1)Pourquoi apparu & comment vrifi : identifier chaque cause premire de l'apparition du problme. A-t-il t activ et dsactiv ? Comment ? A vrifier sur la base de donnes statistiques/vrifications d'hypothses. Si une vrification par une activation/dsactivation n'est pas possible, l'identifier comme une cause premire possible.Ecart : quels sont les risques d'carts au niveau du process, c.--d. combien d'installations ralisent le mme process ? Combien de cellules de soudage ou de robots ? Etc.2)Pourquoi expdi & comment vrifi : identifier chaque cause premire de la non-identification du problme. A-t-il t activ, puis dsactiv ? Comment ? A vrifier sur la base de donnes statistiques/vrifications d'hypothses. Si une vrification par une activation/dsactivation n'est pas possible, l'identifier comme une cause premire possible.ACTION CORRECTIVE PERMANENTERemarque : le formulaire contient des champs permettant de dcrire une seule cause premire. Si d'autres causes premires sont identifies, "copier" les lignes 32-40 (points 1-5) et "coller" les cellules correspondantes afin de crer des champs supplmentaires.1)Action corrective pour la question "Pourquoi apparu" : identifier une/des action(s) corrective(s) permanente(s) prvue(s) pour traiter la cause premire.2)Action corrective pour la question "Pourquoi expdi" : identifier une/des action(s) corrective(s) permanente(s) prvues pour traiter la cause premire.VERIFICATON DES ACTIONS CORRECTIVES1)Le problme a-t-il t activ et dsactiv ? Comment ? Vrification sur la base de donnes statistiques/vrifications d'hypothses. L'action corrective doit tre vrifie pour chaque point sous "Pourquoi apparu" et sous "Pourquoi expdi".2)Nom/Numro tl./adresse e-mail du responsable de l'action corrective : informations relatives la personne charge de mettre l'action corrective en uvre.3)Date d'excution prvue : date d'ici laquelle toutes les actions correctives seront mises en uvre pour cette cause premire.4)Date de fabrication des produits certifis : "point propre" partir duquel tous les produits sont certifis corrects.5)Comment les nouvelles pices seront-elles identifies ? couleur , taille, emplacement, et contenu de l'tiquette ou de l'identification manuscrite sur chaque pice et/ou container de produits certifis.PREVENTION1)Comment ce problme sera-t-il vit l'avenir ? Identifier les modifications systmatiques qui seront mises en place afin de prvenir toute rapparition du problme. Le cas chant, standardiser les amliorations dans d'autres zones " risque".2)La documentation requise a-t-elle t mise jour ? Identifier les documents qui doivent tre mis jour afin d'intgrer les actions correctives permanentes, et prciser la personne responsable des mises jour ainsi que la date d'ici laquelle les documents seront mis jour. Saisir "S.O." si une mise jour des documents n'est pas requise.CLOTURE1)Dclaration de clture : "Clture du probme" (commencer pas les mots placs entre "", puis dcrire la justification de la clture.)2)Version 1.6: IRIS R.11.1 enhancements update.

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French PAR - 8D FormRapport d'analyse des problmes 8DClient :Date d'apparition du problme :Programme :Date de remise du 4D :Produit :Date de remise du 8D :N problme :Date de clture du problme :Les fournisseurs doivent au moins remplir les zones surlignes en jaune pour le formulaire 4D. (Utilisez les instructions dan l'ongelt prcdent pour plus de dtails). Les valeurs numeriques telles que les dates, les numros de tlphone doit tre en format numrique.1. Membres d'quipeNom du ChampionFonction du ChampionNumro tl. du ChampionAdresse e-mail du ChampionAjouter le nom du/des membre(s) d'quipeFonction(s)Numro(s) de tlphoneAdresse(s) e-mail2. Description du problmeDescription (dcrire le problme en rpondant aux questions : quoi, o, quand et combien)Impact sur le client (identifier le risque d'arrt de la production, d'interruptions sur la chane, de rappel de produits, de garantie, etc.)Sites concerns (client, JCI et fournisseurs)3. Containment provisoireQuelles mesures ont t prises afin de protger immdiatement le client et d'isoler tout stock suspect ?Risque pour quel autre produit/plateforme ?Identification des produits certifis ?Rsultats du tri (heure, date, nombre total de produits tris et quantit refuse)Date de dbut du containment provisoire DD.MM.YYYYPour les demandes 8D le fourniesseur doit au moins remplir les zones en vert dans le formulaire. (Utilisez les instructions dans l'onglet prcdent). Les valeurs numeriques telles que les dates, les numros de tlphone doit tre en format numrique.4. Cause premireCAUSE PREMIERE N 1Pourquoi apparu & comment vrifiPourquoi expdi & comment vrifiCAUSE PREMIERE N 2Pourquoi apparu & comment vrifiPourquoi expdi & comment vrifi5. Action corrective permanenteCAUSE PREMIERE N 1Action corrective pour la question "Pourquoi apparu"Action corrective pour la question "Pourquoi expdi"CAUSE PREMIERE N 2Action corrective pour la question "Pourquoi apparu"Action corrective pour la question "Pourquoi expdi"6. Vrification des actions correctivesVrification de l'action corrective : le problme a-t-il t activ et dsactiv ? Comment ? Vrification sur la base de donnes statistiques / vrifications d'hypothses. L'action corrective doit tre vrifie pour chaque point sous "Pourquoi apparu" et sous "Pourquoi expdi".Nom du responsable de l'action corrective (A.C.)Numro tl. responsable A.C.Adresse e-mail responsable A.C.Date d'excution prvue DD.MM.YYYYDate de fabrication des produits certifis DD.MM.YYYYComment les nouvelles pices seront-elles identifies ?7. PrventionComment ce problme sera-t-il vit l'avenir ?La documentation requise a-t-elle t mise jour ?Document concernResponsable des mises jourDate d'excution prvue DD.MM.YYYYAMDEC de conceptionAMDEC de processPlan de surveillanceDroulement du processusInstructions de servicePlansNormes de conception8. CltureDclaration de clture

InstructionsInstructions for the 8D Problem Analysis Report8D13 8D 8 8DsSMRR 4Ds/8DHEADER 1)Supplier/Location: (e.g., ABC Plastics, Markham, Ontario)/ 2)Customer: (e.g., Daimler-Chrysler) 3)Program: (e.g., LH) LH4)Product: (e.g., Overhead System) \5)Issue #: JCI issue tracking # (May also include Customer or Supplier tracking #) JCI6)Date Issue Occurred: Open date for the issue 7)4D Due Date: Default is 24 hours from date issue occurred 4D248)8D Due Date: If applicable. Default is 1 week from date issue occurred 8D19)Date Issue Closed: All permanent corrective actions have been implemented and their effectiveness validated; All required support documents have been submitted. 1. 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. ///Email4D/8D2)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. ///Email 2. 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 vehicles? When shipped from OEM? Detection: How was AG made aware of the issue? Who provided the information?AGExtent: 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, JCI and any Suppliers 3. 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 verif2)Other Product/Platform at Risk: Other JCI lines or Customers who may be impacted by this issue/JCI3)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, JCI, Supplier) JCI5)Interim Containment Start Date: Date 4 ROOT CAUSE Note: The form provides fields for documentation of a single root cause. If additional root causes are identified, "Copy" rows 27-31 and "Insert Cut Cells" to create additional fields.17311)Why Made & How Verified: Identify each root cause for why the issue occurred. Has it been turned on and off? How? Verify 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? Verify through statical evidence/hypothesis testing. If not verified by turning on/off, identify as a suspected root cause. 5. 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.32401)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. 6. VERIFICATION 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.//Email3)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. / 7. 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)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 8. CLOSURE 1)Closure Statement: Close issue (Begin with words noted in followed by the rationale for closure.)

Form8D Problem Analysis Report8DSupplier/:Customer/:Date Issue Occurred/:Program/:4D Due Date/4D:Product/:8D Due Date/8D:Issue/:Date Issue Closed/: 1. Team Members Champion NameChampion TitleChampion Phone NumberChampion E-mail AddressE-mailAdditional Team Member Name(s) Title(s)Phone Number(s)E-mail Address(es)E-mail2. Problem Description Description (Describe issue in terms of what, where, when and how many)Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..) Facilities Involved (Customer, JCI and any Suppliers)3. Interim Containment What actions were taken to immediately protect the customer and contain any suspect inventory?Other Product/Platform at Risk ?Identification of certified material ? Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected)Interim Containment Start Date MM/DD/YYYY8D 4. Root Cause ROOT CAUSE # 1/Why Made & How Verified/Why Shipped & How Verified/ROOT CAUSE # 2/Why Made & How Verified/Why Shipped & How Verified/5. Permanent Corrective Action ROOT CAUSE # 1/Corrective Action for Why Made /Corrective Action for Why Shipped /ROOT CAUSE #2/Corrective Action for Why Made /Corrective Action for Why Shipped /6. Verification of Corrective Actions Verification of Corrective Action: 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./Corrrective Action Owner NameC.A. Owner Phone NumberC.A. Owner E-mail AddressE-mailTarget Completion Date MM/DD/YYYYBuild Date for Certified Material MM/DD/YYYYHow Will New Parts Be Identified?7. Prevention How will this issue be avoided in the future? /Has the necessary documentation been updated?/Affected Document/Owner for Update/Date/ MM/DD/YYYYDFMEAPFMEAControll PlanProcess flowOperation InstructionsDrawingDesign standards8. Closure Closure Statement/

Concept DevelopmentProduct DefinitionAdvanced Development

Instructions Instructions for the 8D Problem Analysis Report8D . -4D 1~3 . -8D ( 8 ) 4D . 4D 8D SMRR DMR . 4D () . 4D 8D .HEADER 1)Supplier/Location: (e.g., ABC Plastics, Markham, Ontario)/ : ..2)Customer: (e.g., Daimler-Chrysler) : 3)Program: (e.g., LH) LH4)Product: (e.g., Overhead System) : 5)Issue #: JCI issue tracking # (May also include Customer or Supplier tracking #) JCI 6)Date Issue Occurred: Open date for the issue 7)4D Due Date: Default is 24 hours from date issue occurred 4D 248)8D Due Date: If applicable. Default is 1 week from date issue occurred 8D , 19)Date Issue Closed: All permanent corrective actions have been implemented and their effectiveness validated; All required support documents have been submitted. 1. 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. ///4D/8D 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. ()/()/()/() 2. 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 vehicles? When shipped from OEM? () ? OEM Detection: How was AG made aware of the issue? Who provided the information? AG 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, JCI and any Suppliers , 3. 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 verif ? ? ? ?2)Other Product/Platform at Risk: Other JCI lines or Customers who may be impacted by this issue/JCI3)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, JCI, Supplier) ,, - JCI5)Interim Containment Start Date: 4 ROOT CAUSE Note: The form provides fields for documentation of a single root cause. If additional root causes are identified, "Copy" rows 27-31 and "Insert Cut Cells" to create additional fields. 1 , , 27-31 "insert Cut Cells" 1)Why Made & How Verified: Identify each root cause for why the issue occurred. Has it been turned on and off? How? Verify 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? Verify through statical evidence/hypothesis testing. If not verified by turning on/off, identify as a suspected root cause. & ? 5. 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 , , 32-40 "insert Cut Cells" 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. : 6. VERIFICATION 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. 7. 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)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 ? 8. CLOSURE 1)Closure Statement: Close issue (Begin with words noted in followed by the rationale for closure.)

Form 8D 8D Problem Analysis Report8D Supplier/:Customer/:Date Issue Occurred/:Program/:4D Due Date/4D:Product/:8D Due Date/8D:Issue/#:Date Issue Closed/:4D . ( ) , 1. Team Members Champion Name Champion Title Champion Phone Number Champion E-mail Address E-mailAdditional Team Member Name(s) Title(s)Phone Number(s)E-mail Address(es)E-mail2. Problem Description Description (Describe issue in terms of what, where, when and how many)( )Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..) ( , )Facilities Involved (Customer, JCI and any Suppliers) ( , )3. Interim Containment What actions were taken to immediately protect the customer and contain any suspect inventory? , ?Other Product/Platform at Risk ?/ ?Identification of certified material ? ?Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected) ( ,, )Interim Containment Start Date/ MM/DD/YYYY8D . ( ) , 4. Root CauseROOT CAUSE #1 / #1Why Made & How Verified/ & ?Why Shipped & How Verified/ ?ROOT CAUSE # 2/#2Why Made & How Verified/ & ?Why Shipped & How Verified/ ?5. Permanent Corrective Action ROOT CAUSE # 1/#1Corrective Action for Why Made / Corrective Action for Why Shipped / ROOT CAUSE #2/ #2Corrective Action for Why Made / Corrective Action for Why Shipped / 6. Verification of Corrective Actions Verification of Corrective Action: 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./ : ? ? / Corrrective Action Owner Name C.A. Owner Phone NumberC.A. C.A. Owner E-mail AddressC.A E-Mail Target Completion Date MM/DD/YYYYBuild Date for Certified Material MM/DD/YYYYHow Will New Parts Be Identified? 7. Prevention How will this issue be avoided in the future? / ?Has the necessary documentation been updated?/ ?Affected Document/ Owner for Update/Date/ MM/DD/YYYYDFMEAPFMEAControll PlanProcess flowOperation InstructionsDrawingDesign standards8. Closure Closure Statement/

Concept DevelopmentProduct DefinitionAdvanced Development

Portuguese InstructionsInstrues para o Relatrio de Anlise do Problema 8DPor favor, leia estas instrues cuidadosamente antes de preencher este formulrio. A 4D pedido requer que voc preencha o formulrio da Disciplina de 1 a 3. Um 8D pedido requer que sua 4D actualizar a informao completa e todas as demais disciplinas (a 8). Devido datas para 4D e 8Ds so claramente especificados no SMRR ou DMR relatrio que foi anexado ao original e-mail avisando do problema. 4Ds so necessrias para garantir que o fornecedor tome aes imediatas em suas instalaes e / ou armazm para assegurar que a questo est contido. Est obrigada a responder por e-mail a todas as partes copiadas no original e-mail com a resposta apropriada 4D ou 8D.CABEALHO1)Fornecedor: (e.g. ABC Plastics, Markham, Ontario)2)Cliente: (e.g., Johnson Controls, Inc., Markham, Ontario)3)Programa: (e.g., LH)4)Produto: (e.g., Overhead System)5)N da 8D: Nmero de controle da JCI (pode tambm incluir o nmero do cliente ou do fornecedor)6)Data de Ocorrncia: Data de abertura para o problema7)Data de 4D: O padro 24 horas partir da ocorrncia do problema.8)Data de 8D: Se aplicvel. O padro 1 semana aps a ocorrncia do problema.9)Data de Fechamento: Toda ao corretiva foi implementada sua respectiva eficcia validada; Todos os documentos requeridos/solicitados foram submetidos.Disciplina1. MEMBROS DO TIME1)Nome do Responsvel/ Cargo/Telefone/ E-Mail: Informaes de contato da pessoa que est liderando (responsvel) pela ao corretiva e submio da 4D/8D.2)Nome(s) do(s) membro(s) adicionais do Time/ Cargo(s)/ Telefone(s)/ E-mail(s): Informaes de contato dos membros do time que compartilham da responsabilidade para as aes corretivas.Disciplina 2. DESCRIO DO PROBLEMA1)Descrio: Descrever o problema pela perspectiva do cliente; o que eles poderiam saber?Quando: Quando as peas foram manufaturadas? Quando elas foram montadas? Quando as peas montadas foram enviadas ao cliente? Quando foram montadas no veculo?Deteco: Como a JCI ficou ciente do problema? Quem forneceu a informao?Exteno: Quantas peas so suspeitas? Proporo suspeita encontrada. De onde vieram os dados - da JCI, do trnsito, do cliente.Modo de falha: Como o problema se manifestou?2)Impacto no Cliente: Identificar potencial de suspenso de entrega, parada de linha, campanha de ptio, garantia, etc.3)Instalaes/Recursos Envolvidos: Cliente, JCI e FornecedoresDisciplina 3. PERODO DE CONTENO1)Quais aes foram tomadas de imediato para proteger o cliente e conter qualquer material suspeito (em inventario)? Desde a notificao inicial, como ns estamos contendo este problema? Qual o status atual da conteno? Quais critrios estamos tomando, onde e como esto sendo verificados se so eficazes? Se comear um plano de retrabalho ou de melhoria - como verificamos a eficcia - anexar plano com registros e grficos de tendncia .2)Outro Produto/Plataforma em Risco: Outras linha JCI ou Clientes JCI que podem ser afetados por este problema.3)Identificao do material aprovado: Cor, tamanho, localizao, descritivo da etiqueta ou identificao feita mo em cada pea e/ou embalagem de material aprovado.4)Resultados da Verificao: Hora, data, quantidade total de peas verificadas e quantidade de peas defeituosas - danificadas no processo (exemplo: Cliente, JCI, Fornecedor)5)Quantidade Verificada: Quantidade total de peas verificada encontradas em todos os processos/fbricas.6)Quantidade Defeituosa: Quantidade de peas defeituosas encontradas em todos os processos/fbricas.7)Data Inicial do Perodo de Conteno: Data Inicial do Perodo de Conteno.Disciplina 4. CAUSA RAZAviso: O formulrio fornece campos para a documentao de uma nica causa da raiz. Se forem identificadas causas razes adicionais copie a linhas 27-31 e insira clulas cortadas" para criar campos adicionais.1)Por que foi produzido e como foi verificado: Identificar cada causa raz focando por que ocorreu o problema. O problema foi resolvido? Como? Verificar atravs de evidncias estatsticas/teste de hipteses. Se no foi resolvido, identificar a causa raz suspeita.Abrangncia: Quais so as oportunidades de abrangncia do processo, por exemplo: quantos dispositivos fazem o mesmo processo? Quantas clulas de solda ou robs? Etc...2)Porque foi enviado e como foi verificado: Identificar cada causa raz focando por que ocorreu o problema. O problema foi resolvido? Como? Verificar atravs de evidncias estatsticas/teste de hipteses. Se no foi resolvido, identificar a causa raz suspeita.Disciplina 5. AO CORRETIVA PERMANENTEAviso: O formulrio fornece campos para a documentao de uma nica causa da raiz. Se forem identificadas causas razes adicionais copie a linhas 32-40 (passos 1-5) e insira clulas cortadas" para criar campos adicionais.1)Ao Corretiva para o por que foi produzido: Identificar ao(es) corretiva(s) permanente atacando a causa raz.2)Ao Corretiva para o por que foi enviado: Identificar ao(es) corretiva(s) permanente atacando a causa raz.Disciplina 6. VERIFICAO DAS AES CORRETIVAS1)O problema foi contido? Como? Verificao atravs de evidncia estatstica/ testes de hipteses. Verificao da ao corretiva para cada porque foi produzido e porque foi enviado2)Responsvel pela Aao Corretiva/Telefone/Email: Contatar a informao para a pessoa responsvel pela implementao, execuo da ao corretiva.3)Data de implementao: Data na qual todas as aes corretivas foram executadas/implementadas4)Colocar uma data para ponto de corte: "Ponto de corte" certificando que todo material est OK.5)Como as peas novas sero identificadas? Uso de Spot, Lote, embalagem, FEM, marcador industrial, etc.Disciplina 7. PREVENO1)Como este problema ser evitado no futuro? Identificar mudanas no sistema ou processo que sero tomadas para previnir que o problema ocorra novamente. Se aplicvel, padronizar a ao corretiva em outras reas de risco.2)Outros facilitadores ou Plataformas de risco? Identificar nome, # pea, responsvel pelo acompanhamento e resultado da ao corretiva e a data combinada para facilitadores ou plataformas que podem correr o risco de ocorrncia do mesmo problema. Digitar "N/A" se for um problema isolado. "Copiar" linhas 48-49 e "Inserir clulas cortadas" para criar campos adicionais se necessrios.3)A documentao necessria tem sido atualizada? Identificar os documentos que devem ser atualizadaos para incluir as aes corretivas permanentes, junto com o responsvel pelas atualizaes e as datas que sero feitas. Colocar N/A se o documento no precisar ser alterado/atualizado.Disciplina 8. FECHAMENTO1)Relato do fechamento: Problema Fechado" (Inicia com palavras conhecidas "" seguidas de argumentos, lgicas para o fechamento)

Portuguese PAR - 8D Form8D Relatrio de Anlise do ProblemaFornecedor:Cliente:Data de Ocorrncia:Programa:Data de 4D:Produto:Data de 8D:Nmero da 8D :Data de fechamento:Para 4D Fornecedores pedidos devem, no mnimo, preencher o formulrio de reas destacadas em amarelo. (Use Instrues no guia anterior para mais detalhes). reas que exigem valores numricos, tais como datas, nmeros de telefone deve ser numrico formato1. Membros do timeNome do responsvel:Cargo do responsvelTelefone do responsvelE-mail do responsvelMembros do timeCargos (time)Telefones (time)E-mails (time)2. Descrio do ProblemaDescrio (Descreva o problema em termos de o que, onde, quando e quantos)Impacto no Cliente (Identificar o potencial de suspenso de entregas, parada de linha, campanha de ptio, garantia, etc.)Instalaes/Recursos Envolvidos (Cliente, JCI e Fornecedores)3. Perodo de ContenoQuais aes foram tomadas de imediato para proteger o cliente e conter qualquer material suspeito (em inventario)?Outro produto/ plataforma em risco?Identificao do material aprovado?Resultados da Verificao (Hora, Data, Quantidade Total de Peas Verificadas e Quantidade de Peas Defeituosas)Quantidade VerificadaQuantidade DefeituosaData Inicial do Perodo de Conteno DD.MM.YYYYPara 8D pedidos fornecedor deve, no mnimo, preencher o formulrio para as reas destacadas em verde. Formato (Use as instrues no guia anterior) reas que exigem valores numricos, tais como datas, nmeros de telefone deve ser numrico4. Causa RazCAUSA RAZ # 1Por que foi produzido e como foi verificado?Por que foi enviado e como foi verificado?CAUSA RAZ #2Por que foi produzido e como foi verificado?Por que foi enviado e como foi verificado?5. Ao Corretiva PermanenteCAUSA RAZ #Ao Corretiva para o por que foi produzido.Ao Corretiva para o por que foi enviado.CAUSA RAZ #2Ao Corretiva para o por que foi produzido.Ao Corretiva para o por que foi enviado.6. Verificao das Aes CorretivasVerificao da Ao Corretiva: O problema foi resolvido? Como? Verificao atravs de evidncia estatstica/ testes de hipteses. Verificao da ao corretiva para cada item de por que foi produzido e por que foi enviado.Responsvel pela Ao CorretivaTelefone (Responsvel pela A.C.)E-mail (Responsvel pela A.C.)Data de Concluso Proposta DD.MM.YYYYData do Material Ok (Ponto de Corte) DD.MM.YYYYComo as peas novas sero identificadas? (Spot, marcador industrial, FEM, etc)7. PrevenoComo este assunto ser evitado no futuro?Outros Instalaes/recursos ou plataformas em riscoNomeNmero da peaResponsvel da A.C. para Follow upData de ConclusoA documentao necessria foi atualizada?Documentos afetadosResponsvel para AtualizaoData DD.MM.YYYYDFMEAPFMEAPlano de ControleFluxo de ProcessoInstrues de TrabalhoDesenhoPadres do Projeto8. FechamentoRelato do fechamento

Desenvolvimento de ConceitoDefinio do ProdutoDesenvolvimento Avanado

Spanish InstructionsInstrucciones para el Reporte de Anlisis de Problemas 4D y 8DPor favor lea las instrucciones cuidadosamente antes de completar esta forma. Una solicitud de 4D requiere que llene las Disciplinas 1 a la 3. Una solicitud de 8D requiere que actualize la informacion de 4D y complete el resto de las Disciplinas (hasta la 8). Las fechas estipuladas para las 4D y 8Ds estan claramente especificadas en el reporte SMRR o DMR que fue adjuntado al correo original notificandolo del problema. Las 4Ds son requeridas para asegurar que el proveedor tome acciones inmediatas en su planta y/o almacen para asegurar que el problema ha sido contenido. Es requerido que usted conteste via correo electrnico a todas las personas copiadas en el correo electrnico original con la respuesta de 4D u 8D apropiada.ENCABEZADO1)Proveedor/Ubicacin: (ej., ABC Plastics/Markham, Ontario)2)Cliente: (ej., JCI San Antonio)3)Programa: (ej., Light Commercial Chiller etc.,)4)Producto: (ej., Compresor o motor etc)5)Problema #: # interno de JCI (SMRR or DMR #)6)Fecha de Ocurrencia: Fecha en que se presento el problema7)Fecha de cierre de 4D: Por default es 24 horas de la fecha de ocurrencia8)Fecha de cierre de 8D: Si aplica. Por default es 7 dias hbiles de la fecha de ocurrencia9)Fecha de Terminacin: Todas las acciones correctivas permanentes han sido implementadas y su efectividad validada; Todos los documentos de suporte has sido enviados.Disciplina 1. MIEMBROS DEL EQUIPO1)Nombre del Lder/Ttulo/Telfono/Correo electrnico: Informacion para contactar al individuo que est lidereando la accin corrective y enviando la 4D/8D.2)Nombre de los Miembros del Equipo/Ttulos/Telfonos/Correo electrnico: Informacin para contactar a los miembros del equipo multi-funcional que comparten la responsabilidad de las acciones correctivas.Disciplina 2. Descripcin del Problema1)Descripcin: Describa el problema desde la perspectiva del cliente; que es lo que ellos saben?Cundo: Cundo fueron fabricadas las piezas? Cundo fueron ensambladas? Cundo fueron embarcados los ensambles al cliente? Cundo fueron ensamblados en los ensambles?Deteccin: Cmo se enter JCI del problema? Quin proporcion la informacin?Extencin: Cuntas unidads son sospechosas? Cul es la proporcin que se encuentra sospechosa. De dnde provienen los datos - en planta, en trnsito, con cliente.Modo de Falla: Cmo se manifiesta el problema?2)Impacto en el Cliente: Identificar el potencial de parar la lnea, de interrupciones, reclamaciones de campo, garantas, etc.3)Entidades Involucradas: Cliente, JCI y otros proveedoresDisciplina 3. ACCION DE CONTENCION1)Qu acciones son tomadas de inmediato para proteger al cliente y contener cualquier inventario sospechoso? Desde la notificacin original, como se esta conteniendo el problema? Cul es el estatus actual de la contencin? Qu tipo de seleccin se ha llevado a cabo, dnde y cmo se ha llevado a cabo la verificacin de la efectividad? Si un plan de retrabajo o reabasto se ha comenzado - cul es y cmo se ha verificado la efectividad? adjunte el plan con sketches y grficas de tendencia.2)Otro Producto/Plataforma en Riesgo: Otros productos de JCI o ubicaciones que puedan ser impactadas por este problema.3)Identificacin del Material Certificado: Color, tamao, ubicacion, y contenido de la etiqueta o identificacin escrita a mano en cada pieza y/o contenedor del material certificado.4)Resultados de la Seleccin: Hora, fecha, total de piezas seleccionadas y cantidad rechazada - desglozado por planta (ej., en JCI, Proveedor, Almacen, etc)5)# Inspeccionados: Cantidad total de piezas seleccionadas en todas las plantas.6)# Defectuosos: Cantidad total de piezas defectuosas en todas las plantas.7)Fecha de inicio de Accin de Contencin: Fecha cuando la accin de contencin comenz.Disciplina 4. CAUSA RAIZ1)Por qu se origin y Cmo fue verificado: Identificar cada causa raz para el origen del problema. Se ha probado? Cmo? Verificar por medio de evidencia estadstica/prueba de hiptesis. Si no se ha verificado, identificarla como una causa raz potencial.Variacion: Cuales son las oportunidades de variacion en el proceso, ej. cuantas plantillas realizan el mismo proceso? Cuando robots? Etc.2)Por qu se escap y Cmo fue verificado: Identificar cada causa raz para el origen del problema. Se ha probado? Cmo? Verificar por medio de evidencia estadstica/prueba de hiptesis. Si no se ha verificado, identificarla como una causa raz potencial.Disciplina 5. ACCION CORRECTIVA PERMANENTE1)Accin correctiva para el origen: Identificar la(s) accion(es) correctiva(s) permanentes planeadas para atacar la causa raiz.2)Accin correctiva para el escape: Identificar la(s) accion(es) correctiva(s) permanentes planeadas para atacar la causa raiz.Disciplina 6. VERIFICACION DE LAS ACCIONES CORRECTIVAS1)Se ha probado? Cmo? Verificar por medio de evidencia estadstica/prueba de hiptesis. Si no se ha verificado, identificarla como una causa raz potencial. Se requiere verificacin de la accin correctiva para cada origen y escape.2)Nombre del responsable de la AC/Telfono/Correo electrnico: Informacin del contacto del individuo o individuos responsables de la implementacin de accin correctiva.3)Fecha compromiso de la accin correctiva: Fecha en que todas las acciones correctivas para la causa raz sern implementadas.4)Fecha del producto certificado: Fecha de inicio en donde el material es certificado como bueno.5)Cmo sern identificadas las piezas nuevas? Color, tamao, ubicacin, y contenido de la etiqueta o identificacin escrita a mano en cada pieza y/o contenedor del material certificado.Disciplina 7. PREVENCION1)Cmo ser evitado este problema en el futuro? Identificar cambios sistemticos que sern puestos en marcha para prevenir que el problema ocurra nuevamente. Si aplica, estandarizar las mejoras en otras reas en riesgo.2)Otras Entidades o Plataformas en riesgo? Identificar el nombre, # parte, responsable de accin correctiva para el seguimiento y la fecha compromiso para alguna otra entidad o plataforma que pueda estar en riesgo con el mismo problema. Colocar "N/A" si el casi es aislado. "Copiar" los renglones 48-49 e "Insertar celdas copiadas" para crear campos adicionales si es requerido.3)Ha sido actualizada la documentacin necesaria? Identificar los documentos que deben ser actualizados para incluir las acciones correctivas permanentes, junto con el responsable de las actualizaciones y las fechas en las que sern actualizados. Colocar "N/A" si los documentos no requieren actualizacin.Disciplina 8. CIERRE1)Enuciado de Cierre: El problema ha sido cerrado (Comenzar con las palabras en seguido de un razonalizacin del cierre.)VERSION OF DOCUMENT1)Version 1.5: Formatting text fields imposed.2)Updated work instructions and added Supplier Name/Location to Header3) 4D and 8D color coded 2/28/2010

Spanish PAR -8D FormReporte de Anlisis del Problema 8DProveedor/Ubicacin:Cliente:Fecha de Ocurrencia:Programa:Fecha de cierre de 4D:Producto:Fecha de cierre de 8D:Problema #:Fecha de Terminacin:Para solicitudes de 4D, los proveedores deben por lo menos completar las reas en amarillo. (Utilizar instrucciones en la ceja anterior para mayores detalles). Las reas que requieren valores numricos como las fechas, nmeros telefnicos deben estar en formato numrico.1. Miembros del equipoNombre del LderTtulo del LderTelfono del LderCorreo electrnico del LderNombre de los miembros del equipoTitulo de los miembrosTlefono de los miembrosCorreo electrnico de los miembros2. Descripcin del problemaDescripcin (Describa el problema utilizando QU, DNDE, CUNDO y CUNTOS)Impacto en el Cliente (Identifique los paros de lnea, interrupciones, reclamaciones de campo, garantas potenciales, etc.)Entidades involucradas (Clientes finales, JCI y otros proveedores)3. Accin de ContencinQu acciones son tomadas para proteger de inmediato al cliente y contener cualquier inventario sospechoso?Otros productos / Plataformas en riesgo?De qu manera se identifica el material certificado?Resultados de la seleccin (Tiempo, Fecha, Nmero Total de Materiales Seleccionados y Cantidad Rechazada).Fecha de inicio de accin de contencin DD.MM.YYYYPara solicitudes de 8D, los proveedores deben por lo menos completar las reas en verde. (Utilizar instrucciones en la ceja anterior). Las reas que requieren valores numricos como las fechas, nmeros telefnicos deben estar en formato numrico.4. Causa RazCAUSA RAZ #1Por qu se origin y Cmo fue verificada la causa?Por qu se escap y Cmo fue verificada la causa?CAUSA RAZ #2Por qu se origin y Cmo fue verificada la causa?Por qu se escap y Cmo fue verificada la causa?5. Accin Correctiva Permanente ActionCAUSA RAZ #1Accin Correctiva para el por qu se originAccin Correctiva para el por qu se escapCAUSA RAZ #2Accin Correctiva para el por qu se originAccin Correctiva para el por qu se escap6. Verificacin de Acciones CorrectivasVerificacin de Accin Correctiva: Se ha verificado el problema? De qu manera? Verificacin mediante evidencia estadstica / prueba de hiptesis? La verificacin de cada accin correctiva para origen y escape es requerida.Nombre del responsable de la ACTelfono del responsable de la ACCorreo electrnico del responsibleFecha compromiso para la AC DD.MM.YYYYFecha del producto certificado DD.MM.YYYYCmo sern identificadas las piezas nuevas?7. PrevencinCmo ser evitado este problema en el futuro?Otras Entidades o Plataformas en RiesgoNombreNmero de parteResponsable del seguimientoFecha CompromisoHa sido actualizada la documentacin necesaria?Documento afectadoResponsable de la actualizacinFecha DD.MM.YYYYDFEMAPFMEAPlan de ControlDiagrama de ProcesoInstrucciones OperativasDibujosEstndares de diseo8. CierreEnunciado de Cierre (Validacin)

Instructions JPInstructions for the 8D Problem Analysis Report8D HEADER 1)Customer: (e.g., Daimler-Chrysler) ( : , , Suzuki )2)Program: (e.g., LH) ( : LH )3)Product: (e.g., Overhead System) ( : Overhead System )4)Issue #: JCI issue tracking # (May also include Customer or Supplier tracking #) : JCI ( )5)Date Issue Occurred: Open date for the issue ( )6)4D Due Date: Default is 24 hours from date issue occurred 4D ( 24 )7)8D Due Date: If applicable. Default is 1 week from date issue occurred 8D ( 1 )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.///E-mail : 4D/8D2)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. ()///E-mail : 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 vehicles? When shipped from OEM? : ? ? ? ? OEM?Detection: How was AG made aware of the issue? Who provided the information? Automotive Group ? ?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, JCI and any Suppliers ( , JCI )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 verify,?2)Other Product/Platform at Risk: Other JCI lines or Customers who may be impacted by this issue JCI 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, JCI, Supplier) ( ,, ) (, , JCI, )5)Sorted #: Total # sorted at all facilities6)Defect #: Total # of defects found at all facilities7)Interim Containment Start Date: DateROOT CAUSE Note: The form provides fields for documentation of a single root cause. If additional root causes are identified, "Copy" rows 27-31 and "Insert Cut Cells" to create additional fields. : . ." 27-31 "INSERT CUT CELLS" 1)Why Made & How Verified: Identify each root cause for why the issue occurred. Has it been turned on and off? How? Verify 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? Verify 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.32401)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.VERIFICATION 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.()// E-mail 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.? ,, content 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 "Insert3)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 CLOSURE 1)Closure Statement: Close issue (Begin with words noted in followed by the rationale for closure.) " " ( "" )

Form JP8D Problem Analysis Report8D Customer/:Date Issue Occurred/:Program/:4D Due Date/4D:Product/:8D Due Date/8D:Issue/:Date Issue Closed/:1. Team Members Champion Name ()Champion Title Champion Phone Number Champion E-mail Address E-mailAdditional Team Member Name(s) Title(s)Phone Number(s)E-mail Address(es)E-mail2. Problem Description Description (Describe issue in terms of what, where, when and how many) (,, )Impact on Customer (Identify the potential for shut down, line interruptions, yard recalls, warranty, etc..) ( ,,,, )Facilities Involved (Customer, JCI and any Suppliers) ( , JCI )3. Interim ContainmentWhat actions were taken to immediately protect the customer and contain any suspect inventory??Other Product/Platform at Risk ??Identification of certified material ??Sorting Results (Time, Date, Total Number Sorted and Quantity Rejected) ( ,, )Interim Containment Start Date MM/DD/YYYY8D4. Root Cause ROOT CAUSE #1/Why Made & How Verified/Why Shipped & How Verified/ROOT CAUSE # 2/#2Why Made & How Verified/Why Shipped & How Verified/5. Permanent Corrective Action ROOT CAUSE #1/Corrective Action for Why Made /Corrective Action for Why Shipped /ROOT CAUSE #2/ #2Corrective Action for Why Made /Corrective Action for Why Shipped /6. Verification of Corrective Actions Verification of Corrective Action: 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./ : ? ? Corrrective Action Owner Name()C.A. Owner Phone NumberC.A. Owner E-mail Address E-mail Target Completion Date MM/DD/YYYYBuild Date for Certified Material MM/DD/YYYYHow Will New Parts Be Identified??7. Prevention How will this issue be avoided in the future? /?Has the necessary documentation been updated?/?Affected Document/Owner for Update/Date/ MM/DD/YYYYDFMEAPFMEAControll PlanProcess flowOperation InstructionsDrawingDesign standards8. Closure Closure Statement/

Concept DevelopmentProduct DefinitionAdvanced Development

Danish InstruktionerInstruktion vedrrende 4D- og 8D-problemanalyserapportDu bedes lse denne vejledning grundigt, fr du udfylder formularen. En 4D-anmodning krver, at du udfylder formularen fra disciplin 1 til og med 3. En 8D-anmodning krver, at du opdaterer 4D-informationerne og udfylder alle resterende discipliner (til og med 8). Deadline for 4D og 8D er tydeligt angivet i SMRR- eller DMR-rapporten, som var vedlagt den oprindelige e-mail, hvor du blev informeret om problemet. 4D skal sikre, at leverandren straks foretager det ndvendige inden for egen virksomhed og/eller i forhold til lagre for at sikre, at problemet inddmmes. Det er ndvendigt, at du svarer pr. e-mail til alle, som var kopieret p den oprindelige e-mail, med den relevante 4D- eller 8D-tilbagemelding.FORMULARHOVED1)Leverandrnavn/-hjemsted: (f.eks. Danfoss/DK)2)Kunde: (f.eks. Johnson Controls Parts Centre, DK)3)Program: (f.eks. Kleautomatik)4)Produkt: (f.eks. Reguleringsventil DN50)5)Sagsnr.: Johnson Controls' referencenummer (SMRR- el. DMR-nummer)6)Dato for problemets opsten: Den dato, hvor sagen blev bnet7)Deadline for 4D: Standardkravet er 24 timer fra problemets opsten8)Deadline for 8D: Hvis relevant. Standardkravet er 7 arbejdsdage fra problemets opsten9)Dato for sagens afslutning: Alle permanente korrigerende handlinger er gennemfrt og effektiviteten valideret. Alle ndvendige dokumenter er fremsendt.Discipline 1Disciplin 1. TEAMDELTAGERE1)Navn p den ansvarlige/titel/telefonnummer/e-mail-adresse: Kontaktoplysninger p den person, der er ansvarlig for den korrigerende handling og fremsendelse af 4D/8D.2)Navne p vrige teamdeltagere/titler/telefonnumre/e-mail-adresser: Kontaktoplysninger p tvrfunktionelle teamdeltagerne, som deler ansvaret for de korrigerende handlinger.Disciplin 2. PROBLEMBESKRIVELSE1)Beskrivelse: Beskrivelse af problemet set fra kundens perspektiv hvilken information har de?Hvornr: Hvornr blev delene fremstillet? Hvornr blev de samlet? Hvornr blev de sammenbyggede dele sendt til kunden? Hvornr blev de monteret i det overordnede produkt?Omfang: Hvor mange enheder er under mistanke? Hvilket forholdsmssigt antal er fundet med mistnkte fejl? Hvorfra kommer data internt, under levering, hos kunden.Opdagelse: Hvordan fik Johnson Controls kendskab til problemet? Hvem kom med oplysningen?Fejltilstand: Hvordan viser problemet sig?2)Indvirkning p kunden: Vurder muligheden for nedlukning, produktionslinjestop, tilbagekaldelsesaktioner, garanti etc.3)Involverede parter: Kunder, Johnson Controls selskaber og leverandrer.Disciplin 3. MIDLERTIDIG INDDMNING1)Hvilke tiltag blev ivrksat straks for at beskytte kunden og inddmme lager af dele, der er under mistanke? Hvordan har vi, siden problemet frst blev kendt, sikret en inddmning? Hvad er nuvrende status p denne inddmning? Hvilken sortering har vi foretaget hvor og hvordan har vi verificeret effektiviteten? Hvis en plan for udbedring eller eftermontering er pbegyndt hvad gr den ud p, og hvordan har vi verificeret effektiviteten? Vedlg plan med skitser og trendgrafer.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)Risiko for andre produkter/-grupper: Andre Johnson Controls produker eller virksomheder, som kan risikere at blive berrt af problemet.3)Identificering af afmrket materiale: Farve, strrelse, placering og indhold af mrkat eller hndskreven identifikation p hver del og/eller container/palle/kasse med afmrket materiale.4)Sorteringsresultater: Tid, dato, samlet antal sorteret og samlet mngde afvist fordelt p de involverede parter (dvs. hos Johnson Controls, leverandrer, lagre etc.).5)Antal sorteret: Samlet antal sorteret hos alle involverede parter.6)Antal fejl: Samlet antal fejl fundet hos alle involverede parter.7)Startdato for midlertidig inddmning: Den dato, hvor den midlertidige inddmning startede.Discipline 4. HOVEDRSAGBemrk: Skemaet indeholder felter til dokumentation af en enkelt rsag. Hvis yderligere rsager er identificeret, "Kopi" rkkerne 27-31 og "Indst Cut Cells" for at oprette yderligere felter.1)Hvorfor opstet & hvordan verificeret: Fastlg hver enkelt hovedrsag til, at problemet kunne opst. Har fejlkilden vret aktiveret/deaktiveret? Hvordan? Bekrft vha. statistisk bevismateriale/hypotesetest. Hvis ikke verificeret vha. aktivering/deaktivering, klassificeres den som en formodet hovedrsag.Variation: Hvilke muligheder er der for variation i processen? Dvs. i hvor mange opstillinger udfres samme proces? Hvor mange svejseceller eller robotter? Etc.2)Hvorfor afsendt & hvordan verificeret: Fastlg hver enkelt hovedrsag til, at problemet ikke blev opdaget. Har fejlkilden vret aktiveret/deaktiveret? Hvordan? Bekrft vha. statistisk bevismateriale/hypotesetest. Hvis ikke verificeret vha. aktivering/deaktivering, klassificeres den som en formodet hovedrsag.Disciplin 5. PERMANENT KORRIGERENDE HANDLINGBemrk: Skemaet indeholder felter til dokumentation af en enkelt rsag verifikation. Hvis yderligere grundlggende rsager er blevet identificeret, "Kopi" rkkerne 32-40 (steps1-5) og "Indst Cut Cells" for at oprette yderligere felter.1)Korrigerende handling for hvorfor opstet: Udpeg, hvilken permanent korrigerende handling(er), der er planlagt for at tage hnd om hovedrsagen.2)Korrigerende handling for hvorfor afsendt: Udpeg, hvilken permanent korrigerende handling(er), der er planlagt for at tage hnd om hovedrsagen.Disciplin 6. VERIFIKATON AF KORRIGERENDE HANDLINGER1)Har fejlkilden vret aktiveret/deaktiveret? Hvordan? Verifikation vha. statistisk bevismateriale/hypotesetest. Der krves verifikation af korrigerende handling for hver enkelt hvorfor opstet og hvorfor afsendt.2)Navnet p ejeren af den korrigerende handling/telefonnummer/e-mail-adresse: Kontaktoplysninger p den person, der er ansvarlig for at gennemfre den korrigerende handling.3)Forventet afslutningsdato: Datoen inden for hvilken alle korrigerende handlinger for denne hovedrsag vil vre gennemfrt.4)Fremstillingsdato for afmrket materiale: Skringspunkt (eller termin), hvor alt materiale er mrket som vrende i orden.5)Hvordan bliver nye dele identificeret? Farve, strrelse, placering og indhold af mrkat eller hndskreven identifikation p hver del og/eller container/palle/kasse med afmrket materiale.Disciplin 7. FOREBYGGELSE1)Hvordan undgs problemet fremover? Angiv hvilke systematiske ndringer, der vil blive ivrksat for at undg, at problemet gentager sig. Hvis relevant standardiseres forbedringerne til at omfatte andre risikoomrder.2)Andre forretningsenheder eller produktgrupper, som kan vre berrt? Udpeg navn, partnummer, ejer af korrigerende handling og ansvarlig for opflgning samt deadline gldende for alle andre forretningsenheder og produktgrupper, som kan vre berrt af samme problem. Skriv N/A (eller ikke relevant), hvis problemet er isoleret. Udfr Copy for rkke 48-49 og Insert Cut Cells for at danne yderligere felter, hvis ndvendigt.3)Er den ndvendige dokumentation blevet opdateret? Fastlg hvilke dokumenter, der skal opdateres, s de indeholder de permanente korrigerende handlinger samt hvem, der er ansvarlig for opdateringerne og inden for hvilke datoer, de vil blive opdateret. Skriv N/A (eller ikke relevant), hvis det ikke er ndvendigt at opdatere dokumentet.Disciplin 8. AFSLUTNING1)Afslutningserklring: Sagen afsluttes . (Indled med ordene i anfrelsestegn og fortst med at forklare rationalet for afslutning af sagen).DOKUMENTVERSION1)Version 1,5: Formatering tekstfelter plagt2)Ver Version 1,6: IRIS R.11.4 forbedringer opdatering.

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Danish Par-8D Form8D problemanalyserapportSkabelon Version 11,4Kunde:Dato for problemets opsten:Program:Deadline for 4D:Produkt:Deadline for 8D:Sagsnr. :Dato for sagens afslutning:For 4D anmodninger skal leverandrerne p et minimum, Udfyld de fremhvede felter i gult. (Se instruktionerne fanen for yderligere detaljer). Omrder, der krver numeriske vrdier ssom datoer og telefonnumre skal vre i en numerisk format.1. TeamdeltagereNavnet p den ansvarligePgldendes titelPgldendes telefonnummerPgldendes e-mail-adresseNavnet p vrige teamdeltagereTitlerTelefonnumreE-mail-adresser2. ProblembeskrivelseBeskrivelse (beskriv problemet ift. hvad, hvor, hvornr og hvor mange)Indvirkning p kunden (vurder muligheden for nedlukning, produktionslinjestop, tilbagekaldelsesaktioner, garanti etc.)Faciliteter involveret (Customer, JCI og eventuelle leverandrer)3. Interim ContainmentHvilke handlinger blev taget til straks beskytte kunden og indeholder en mistnkt beholdning?Risiko for andre produkter/produktgrupper?Identificering af afmrket materiale?Sorteringsresultater (tid, dato, samlet antal sorteret og samlet mngde afvist)Startdato for midlertidig inddmning DD.MM.YYYYFor 8D anmodninger skal leverandrerne p et minimum, udfylde felterne fremhvet med grnt. (Se instruktionerne fanen for detaljer) Omrder der krver numeriske vrdier, ssom datoer eller telefonnumre, skal vre i en numerisk format.4.HovedrsagHovedrsag #1Hvorfor opstet & hvordan verificeretHvorfor afsendt & hvordan verificeretHovedrsag #2Hvorfor opstet & hvorda