Blank 5p 2v50

Instructions Based on the Honda 2005 5-P training, the questions to be answered for each block have been listed. It is recommended that you replace the question(s) with your answer. 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 placed as an attachment. In Box 1B, any of the items listed can be used-- these are meant to be suggestions of the type of information expected. Items can be placed as attachments.

In Box 2C, the root cause analysis can be completed in less than 5 why's. If there are multiple potential ro causes that you would like to countermeasure, the 5 why analysis for each can be added as an attachmen Root causes for BOTH occurrence and for non-detection must be listed. In Box 2D, the explaination of WHY the root cause was selected is to be listed. (The root cause fits all of listed in 1A)

Dates for countermeasures and verifications should be listed. Data ing effectiveness should be pr Honda indicated that 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. Attachments are optional. Any information to help clarify the defect, root cause, show countermeasures, or data to effectiveness is appropriate.

s block have been listed.

uch space in Box 1A,

ions of the type of

ere are multiple potential root n be added as an attachment.

(The root cause fits all of the data

effectiveness should be provided.

ne root cause

PROBLEM STATEMENT <What part model and type has the problem and what is the defect? Only 1 part and 1 defect per sheet>

1-A

5 PRINCIPLES FOR PROBLEM SOLVING WORK SHEET 1-B

PROBLEM DEFINITION (PROBLEM SIDE)

PREPARING SECTION Report to be Made to

SECTION OR SUPPLIER: TBDN Approved By

Approved By

Checked By

Prepared By

SECTION

Approved By

Checked By

PROBLEM DEFINITION (CLARIFYING FACTS) (attach add'l sheets if necessary)

N units were sorted, and n units were found defective. Lot numbers/ sort quantities A. WHO: <Who found the problem> B. WHAT: Part Analysis: equipment?> D. WHEN: K, SPC charts, %NG, Reject History, etc> E. WHY: F. HOW: G. QUANTITY: Why, Why (Both Occurence & Nondetection) (circle causes to be countermeasured) IDENTIFY ROOT CAUSE (causes from 2C to be C/M

2-C

2-D

WHY(1)

WHY(2)

WHY(3)

WHY(4)

WHY(5)

What is the immediate <--- What is the cause <--- What is the cause <--- What is the cause <--- What is the cause cause of the problem? of the previous cause? of the previous cause? of the previous cause? of the previous cause?

and why selected)

The root cause for occurrence is… The root cause for non-detection is… We determined that this is the root cause by... The data show...

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

3

<--- What is the cause <--- What is the cause <--- What is the cause <--- What is the cause of the previous cause? of the previous cause? of the previous cause? of the previous cause?

CORRECTIVE COUNTERMEASURE(S)

Identify Temporary & Permanent, Responsibility and Date

4

CONFIRM COUNTERMEASURE(S)

We took these actions to confirm the countermeasure is in place and working: <Statistical Proof, Supplier Self Audit, C/M Verification, Durability Testing, etc.>

5

/FEEDFORWARD

Vert, Horiz & back to employee The system has been changed to prevent similar occurrences in the future on this and other products. The countermeasures have been applied across <products, production lines, plants, companies> to prevent the same thing from happening elsewhere.

Method

Man

Material

Machine

2-A

Identify Root Cause

(Brainstorming)

Possible Causes

Verification

2-B

Identify Root Cause (Fishbone, Org Chart, Mind-Map, etc… Why, Why Why Analysis)

Other

Attachment A

Attachment B

Attachment C

Attachment D

Attachment E

Attachment E