5P Report by uab11439

VIEWS: 595 PAGES: 9

									INSTRUCTION OF 5P WORK SHEET
                                           In Box 1A, a picture of the defect can also be referenced. Since there is not much space in Box 1A, the picture can be place d as an attachment.
  FRONT SIDE                               A. WHO: <Who found the problem>
                                           B. WHAT: <Reiterate Problem Statement>
                                           C. WHERE: <Location of occurrence and where on the part is the trouble located>
                                           D. WHEN: <Date and time problem was first found, has it reoccurred, is it continuous, sporadic or periodic, and manufacturing date of first observation>
                                           E. WHY: <Content of complaint>
                                           F. HOW: <How was problem found - visual inspection, customer complaint, etc>
                                           G. QUANTITY: <How many parts or units have this problem, how many defects on each object, and is problem getting better, wors e or staying the same>


                                                                                                                                                                                                                                                                                                                Sign and date must be
                                                                                                                                                                                                                                                                                                                       filled in
                                TBDN 5P Number
                                                                                                                                                                                                                                                                   Supplier company
                                                                                                                                                                                                       Temporary action detail                                           name
                                                                                                                                                                                                        Sorting results detail

                                 5 PRINCIPLES FOR PROBLEM SOLVING WORK SHEET
                                                                                                                                                                                                                                                                                                                                     Sign and date must be
                                                                                                                                                                                                                           TBDN QA                                            SUPPLIER or Department Name
                                                                                                                                                                                                                                                                                                                                            filled in
                                 5P Number                                                                                                                                                                                                                         NAME

                                                                                                                                                                                                            Approved By       Checked By     Checked By            Approved     Approved    Checked By   Prepared By

                                 PROBLEM STATEMENT                                                                                                                                                                                                                 By           By



        Actual problem detail
                                                                                                                                                                                                          Date              Date           Date                    Date         Date        Date         Date




                                      1-A                  PROBLEM DEFINITION                                              1-B             Temporary action                                                               1-C              PROBLEM DEFINITION (CLARIFYING FACTS)
                                                           (PROBLEM SIDE)                                                                                                                                                                  (attach add'l sheets if necessary)
                                 A. WHO:                                                                                  Sorting results, Sorting lot / sort QTY                                                         Part Analysis:
                                 B. WHAT:                                                                                 How many units w ere sorted, and how many units w ere found defective.
                                 C. WHERE
                                                                                                                                                                                                                          Process Analysis:
                                 D. WHEN:                                                                                                                                                                                                                            In Box 1C, any of the items listed can be used-- these are meant to
                                 E. WHY:                                                                                                                                                                                                                              be suggestions of the type of information expected. Items can be
                                 F. HOW:                                                                                                                                                                                                                                                     placed as attachments.
                                 G. QUANTITY:                                                                                                                                                                                                                             Part Analysis: <Any of the following - Visual observations,
                                                                                                                                                                                                                                                                       Dimentional comparison, test results, technical reports, changes
                                                       Section 2-A and 2-B must be utilized before move to section 2-C                                                                                                                                              occurring around 1st problem date, new manpower?, new material?,
                                                                                                                                                                                                                                                                                        die adjusted?, new equipment?>
                                          2-C              Why analysis (Both Occurence & Nondetection) (circle causes to be countermeasured)                                                                                2-D IDENTIFY ROOT CAUSE Process Analysis: <Any of the following: Process Flow, flow chart;
                                                                                                                                                                                                                                         (causes from 2C to be C/M and why selected)
                                                                                                                                                                                                                                                                    Statistical History: trends, histogram, CpK, SPC charts, %NG, Reject
                                                            WHY(1)                          WHY(2)                          WHY(3)                          WHY(4)                          WHY(5)                          The root cause for occurrence is…                                      History, etc>
                                                  What is the immediate cause of   <--- What is the cause of the   <--- What is the cause of the   <--- What is the cause of the   <--- What is the cause of the            The root cause for non-detection is…
                                                           the problem?                  prev ious cause?                prev ious cause?                prev ious cause?                prev ious cause?                   We determined that this is the root cause by... The data show ...
                                  OCCURRENCE




   In Box 2C, the root cause analysis can be completed in less
   than 5 why's. If there are multiple potential root causes that
                                      Why was 5 why not
     you would like to countermeasure, thethe problem analysis for the problem not
                                                               Why was                                               Why was the problem not         Why was the problem not         Why was the problem not
                                    detected and Root at the
      each can be added as an attachment.contained causes for and contained at the
                                                             detected                                              detected and contained at the   detected and contained at the   detected and contained at the
                                                                                                                                                                                                                                                                                            After 5 Why analysis are completed, define root cause for
                                  NON DETECTION




                                              source?
      BOTH occurrence and for non-detection must be listed. source?                                                          source?                         source?                         source?
                                                                                                                                                                                                                                                                                                      both occurrence and non detection side
                                                                                                                                                                                                                                                                                              In Box 2D, the explaination of WHY the root cause was
                                                                                                                                                                                                                                                                                            selected is to be listed. (The root cause fits all of the data
                                                                                                                                                                                                                                                                                                                     listed in 1A)
                                                                                                                                                                                                                                                                                              Dates for countermeasures and verifications should be
                                                                                                                                                                                                                                                                                            listed. Data supporting effectiveness should be provided.


                                                  3        CORRECTIVE COUNTERMEASURE(S)                                                                           4       CONFIRM COUNTERMEASURE(S)                                                           5           FEEDBACK/FEEDFORWARD
                                                           Identify Temporary & Permanent, Responsibility and Date                                                                                                                                                        Vert, Horiz & back to employee



     Corrective action must be implemented showing occurrence,
       error proofing and detection. Implementation target date
                           must be shown.



                                                                                                                                Corrective action must be confirmed after implemented. If                                                                                                  Consider YOKOTEN activity. All similer product and process
                                                                                                                               countermeasure is not effective, Additional countermeasure                                                                                                     shoud be reviewed and implement countermeasure.
                                                                                                                                                                                                                                                                   Approved by: N.Oba              Revised: 8/5/07
                                                                                                                                          is necessary to avoid re-occurrence.




                                                                  Attachments are optional. Any information to help clarify the defect, root cause, show countermeasures, or data to verify effectiveness is appropriate.




   BACK SIDE

                                                  2-A              Identify Root Cause (Brainstorming)                                                                                   2-B          Identify Root Cause (Fishbone, Org Chart, Mind-Map, etc)

                                                                      Possible Causes                                                    Verification
                                            Machine
                                            Material




                                                                                                                           Bak side 2 (5-P Backside) was to be use by teams to determine root cause but that
                                                                                                                                      this brainstorming side did not have to be sent to customers.
                                            Man
                                            Method
                                            Other




                                                                                                                                                                                                                                                                    Approved by: N.Oba                             Revised: 8/5/07
5 PRINCIPLES FOR PROBLEM SOLVING WORK SHEET
                                                                                                                                                                                            TBDN QA                                             SUPPLIER or Department Name
5P Number                                                                                                                                                                                                                           NAME
                                                                                                                                                                              Approved By     Checked By    Checked By              Approved       Approved   Checked By   Prepared By
PROBLEM RANK                                         PROBLEM STATEMENT                                                                                                                                                              By             By




                                                                                                                                                                            Date             Date          Date                     Date           Date       Date         Date




     1-A                    PROBLEM DEFINITION                                               1-B             Temporary action                                                               1-C            PROBLEM DEFINITION (CLARIFYING FACTS)
                           (PROBLEM SIDE)                                                                                                                                                                  (attach add'l sheets if necessary)
A. WHO:                                                                                    Sorting results, Sorting lot / sort QTY                                                      Part Analysis:
B. WHAT:                                                                                   How many units were sorted, and how many units were found defective.
C. WHERE                                                                                                                                                                                Process Analysis:
D. WHEN:
E. WHY:
F. HOW:
G. QUANTITY:

                    Section 2-A and 2-B must be utilized before move to section 2-C
        2-C                Why analysis (Both Occurence & Nondetection) (circle causes to be countermeasured)                                                                                 2-D           IDENTIFY ROOT CAUSE
                                                                                                                                                                                                            (causes from 2C to be C/M and why selected)
                             WHY(1)                          WHY(2)                          WHY(3)                          WHY(4)                          WHY(5)                          The root cause for occurrence is…
                    What is the immediate cause of   <--- What is the cause of the   <--- What is the cause of the   <--- What is the cause of the   <--- What is the cause of the           The root cause for non-detection is…
                             the problem?                  previous cause?                 previous cause?                 previous cause?                 previous cause?                   We determined that this is the root cause by... The data show...
OCCURRENCE




                      Why was the problem not          Why was the problem not         Why was the problem not         Why was the problem not         Why was the problem not
                    detected and contained at the    detected and contained at the   detected and contained at the   detected and contained at the   detected and contained at the
                              source?                          source?                         source?                         source?                         source?
NON DETECTION




                3           CORRECTIVE COUNTERMEASURE(S)                                                                             4      CONFIRM COUNTERMEASURE(S)                                                          5           FEEDBACK/FEEDFORWARD
                           Identify Temporary & Permanent, Addition of Error-Proofing                                                       Verfiy the effectiveness of the
                                                                                                                                            countermeasure record verfication date.                                                        Vert, Horiz & back to employee
                           Responsibility and Date




                                                                                                                                                                                                                                    Approved by: N.Oba               Revised: 8/5/07
     2-A   Identify Root Cause (Brainstorming)                  2-B   Identify Root Cause (Fishbone, Org Chart, Mind-Map, etc)

            Possible Causes                      Verification
Machine
Material
Man
Method
Other




                                                                                                       Approved by: N.Oba        Revised: 8/5/07
Attachment A
Attachment B
Attachment C
Attachment D
Attachment E
Attachment E

								
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