Tracking Number: Customer : Response Due Date:

Status

Problem Solving Worksheet

Step 0 1 2 3 4 5 6 7 8
Action Prepare Team Describe Contain Diag. Solve Validate Prevent Wrap

Registered problem and Long Term Corrective Long Term Corrective Long Term Corrective
Short Term Corrective Action developed but not Action implemented. Action confirmed effective.
Action in place in house. implemented. Monitoring/evaluating Problem closed.
effectiveness.
Prepare for Problem Solving - Is an Emergency Response Action Needed?
Does the problem warrant/require an 8D? If (If needed document actions in Action Item Table)
0 so comment why and proceed.

Team Assembled - Establish a small Team Goals:

group of people with the process/product
knowledge, allocated time, authority and skill To identify the root cause of defect and take
1 in the required technical disciplines to solve corrective action.
the problem and implement corrective
actions.
Department Name (Team Leader First) Skills Responsibility

Quality Mr. Shrikanth Sherigar Micro & Macro Inspection, Quality Head
Customer Handling, Metallurgy

Production Mr. Pandurang Kadam Material Inspection – Coils Shift Supervisor

(Visual)

Problem Description - Provides the Sketch of Problem

starting point for solving the problem or
nonconformance issue.
Need to have “correct” problem description to
2A identify causes. Need to use terms that are
understood by all.

Part Number(s):
10.50 mm dia. coil
Customer(s): M/s. NHB Bearings Ltd., Amalsad
List all of the data and documents that might help you to
define the problem more exactly? 1. In-coming Material Inspection Report

Is there an action plan to collect additional information? -

Prepare Process Flow Diagram for problem. (Attach
to PSW)
Problem Description - Combine the relevant information, this will be your Problem
Description

2B Flatness and size variation observed through out the coil. Size observed in the range of 9.35 to
9.85 mm dia.

Interim Containment Actions - Temporary actions to contain the problem

and “fix” until permanent correction is in place. (Note: Validate that the action taken works).
3 Due to flatness customer is not in position to use the material, hence rejected the same.

Document Actions in the Action Item Table

Diagnose Root Cause – Analyze for “Root Cause” of the problem. Identify and
verify the Escape Point.
Material was inspected bySHPL representative and coils were kept aside at rolling mill
but at the time of loading due to oversight of the operator of rolling mill this coils were
loaded and was directly dispatched to NHB Bearings.

Brainstorm the possible causes of the problem (attach)

4A
Reason for the same is lying at the mill.

4A Cause and Effect Diagram (Attach copy of complete diagram(s) as

appropriate)

How made? Why did it get out?

Note on Diagram(s) circle the most likely contributors (3 max) from each side.
 4B 5 – Why Analysis
Why - Why for Generation: Why - Why for Non-Detection:

Ask – Why did this happen? Ask – Why did this happen?

Ask – Why did this happen? Ask – Why did this happen?

Ask – Why did this happen?

Ask – Why did this happen?

Ask – Why did this happen?

Action Plan - Based on the team’s discussions. Begin to complete the Root Cause
Action Plan to verify and validate the root causes and test the escape point. Document this on
4C the Action Item Table.

5 Identify Solutions – Solutions that address and correct the root cause.
Solutions determined to be the best of all the alternatives. Document and verify the
Permanent Corrective Action (PCA) in the Action Item Table.

Sample to be forwarded to supplier for their futuristic analysis and Corrective &
Preventive Action

Validation - Implement and validate to ensure that corrective action does “what it is
6 supposed to do.” Detect any undesirable side effects. Document this on the Action Item Table.
Return to root cause analysis, if necessary.

Prevention (Design / Information Systems Review) - Determine what

7 improvements in systems and processes would prevent problem from recurring. Ensure that
corrective action remains in place and successful.

7B Review the following documents / systems.

Completion Date
Document Accountability
Planned Actual

Management System Manual

Manufacturing Work Instructions

Inspection Work Instructions

Flow Charts

Control Plans
Design FMEA

Process FMEA

Gauges/MMD/IMTE

PPAP

Engineering Change Approval

Manufacturing Forms

Inspection Forms

Material Identification Label

Congratulate Your Team

- Use all forms of employee recognition and document as necessary.
8
Celebrate successful conclusion of the problem solving effort.
Formally disengage the team and return to normal duties.
Was the PSW Effective?

Yes/No Signature/Title Date

Action Item Table

Actions Implement and Verify Actions
Action Fault / Containment/ Corrective How
Verify Action Accountability Planned Actual Status
# Item Action Verified

8
 Registered problem and Short Long Term Corrective Action Long Term Corrective Action Long Term Corrective Action confirmed
Term Corrective Action in place in developed but not implemented. implemented. Monitoring/evaluating effective. Problem closed.
house. effectiveness.
Note: Copy this page and attach as often as necessary