8D Report

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{
  "template_id": "tmpl_your_template_id",
  "format": "pdf",
  "data": {
    "report_number": "8D-2026-0042",
    "revision": "3",
    "status": "Closed, accepted by the customer",
    "customer": "Globex Industries, Ingolstadt plant",
    "customer_reference": "Quality reject QR-88214",
    "supplier": "Northwind Instruments SRL",
    "supplier_code": "GLX-RO-4417",
    "part_number": "NI-6620",
    "part_description": "Sensor cable assembly, 1.8 m, sealed connector both ends",
    "opened_date": "June 22, 2026",
    "response_due": "Initial response June 23, full report July 7, 2026",
    "champion": "Anca Marin, Quality Manager",
    "d0_symptom": "Twelve sensor cable assemblies failed continuity at the customer end of line test with an intermittent open circuit at the crimp end of the connector. All twelve came from deliveries made between June 8 and June 18.",
    "d0_emergency_response": "Shipments of NI-6620 stopped the same day. A certified stock arrangement was put in place from existing finished goods that had passed a 100 percent pull test, so the customer line was not stopped. The customer was notified within four hours of the reject being raised.",
    "d0_date": "June 22, 2026",
    "team": [
      {
        "name": "Anca Marin",
        "function": "Quality",
        "role": "Champion, approves closure"
      },
      {
        "name": "Radu Ilies",
        "function": "Manufacturing engineering",
        "role": "Team leader"
      },
      {
        "name": "Dana Kovacs",
        "function": "Quality engineering",
        "role": "Data, measurement, containment sorting"
      },
      {
        "name": "Tomas Reiner",
        "function": "Maintenance",
        "role": "Crimp tooling and press setup"
      },
      {
        "name": "Sanne Kuipers",
        "function": "Production",
        "role": "Operator practice and shift handover"
      },
      {
        "name": "Elena Fischer",
        "function": "Supplier quality at Globex Industries",
        "role": "Customer representative"
      }
    ],
    "d2_problem_statement": "Since the June 8 build, NI-6620 assemblies show an intermittent open circuit at the connector A crimp under vibration and thermal cycling. Twelve failures in 4,180 pieces delivered, all traced to crimp station operation 40 on the second shift.",
    "problem_specification": [
      {
        "dimension": "What",
        "is": "Open circuit at connector A crimp, conductor pulls out of the barrel under load",
        "is_not": "Connector B crimp, cable insulation, over-mould, or the sensor element itself",
        "distinction": "Connector A is crimped at operation 40; connector B is crimped at operation 55 on a different press"
      },
      {
        "dimension": "Where",
        "is": "Detected at the customer end of line test in Ingolstadt",
        "is_not": "Detected at our own end of line continuity test before dispatch",
        "distinction": "Our test is static and at room temperature; the customer test runs after a thermal soak"
      },
      {
        "dimension": "When",
        "is": "Assemblies built from June 8 onwards, second shift only",
        "is_not": "Builds before June 8, or any first shift build in the same period",
        "distinction": "The crimp die at operation 40 was replaced on June 5 and the second shift ran a different setup sheet revision"
      },
      {
        "dimension": "How big",
        "is": "12 failures in 4,180 delivered, 2,870 ppm",
        "is_not": "A steady background rate, the historic level is under 200 ppm",
        "distinction": "The rate steps up rather than drifting, which points at a change rather than at wear"
      }
    ],
    "containment": [
      {
        "action": "Stop shipment of NI-6620 and quarantine finished goods",
        "quantity": "1,940 pieces in finished goods",
        "owner": "Dana Kovacs",
        "in_place": "June 22, 2026",
        "verification": "Stock record blocked, cage sealed and photographed"
      },
      {
        "action": "100 percent pull test to 60 N on all quarantined and in transit stock",
        "quantity": "1,940 in stock plus 620 in transit",
        "owner": "Dana Kovacs",
        "in_place": "June 23, 2026",
        "verification": "Sort record SORT-2026-0088, 47 pieces rejected, remainder released as certified stock"
      },
      {
        "action": "Sort at the customer plant by a third party",
        "quantity": "3,110 pieces at Globex Industries",
        "owner": "Elena Fischer with the sorting provider",
        "in_place": "June 24, 2026",
        "verification": "Daily sort reports to Globex Industries, 9 further pieces rejected, sort closed July 3"
      },
      {
        "action": "Add a thermal soak plus pull test to the outgoing check until the permanent action is validated",
        "quantity": "Every lot",
        "owner": "Radu Ilies",
        "in_place": "June 25, 2026",
        "verification": "Outgoing check sheet revision B, reviewed daily by quality"
      }
    ],
    "root_causes": [
      {
        "leg": "Occurrence",
        "analysis": "Conductor pulls out of the crimp barrel. Why? Crimp height ran 0.06 mm above the setting. Why? The press was set from the setup sheet without a crimp height study. Why? The die was replaced on June 5 with an identical part number. Why? A like for like die swap is treated as maintenance, not as a process change.",
        "root_cause": "The replacement die had a different effective anvil height within its drawing tolerance, and the press was returned to production on the old setting because no crimp height study was run after the swap.",
        "verification": "Crimp height measured on retained samples from both dies. Cross sections show an under compressed barrel on the June builds. Reinstating the old die and re-running the study reproduced and then removed the defect."
      },
      {
        "leg": "Detection",
        "analysis": "Bad crimps reached the customer. Why? The outgoing continuity test passes an under compressed crimp. Why? It is static and at room temperature. Why? The pull test that would find it runs one piece per 500 at start of shift only. Why? The sample plan was written for a stable process and never revisited after the line speed doubled.",
        "root_cause": "The pull test sample plan at operation 40 could not detect a drift starting mid shift, so the escape went undetected for ten working days.",
        "verification": "Replaying the June records against the new sample plan would have flagged the drift on the second shift of June 9."
      },
      {
        "leg": "Systemic",
        "analysis": "No trigger existed. Why? Tooling replaced with the same part number is not treated as a change. Why? The change control procedure lists design and material changes only. Why? It was written before the crimp cell was installed and never extended. Why? Procedure review is annual and by owner, with no trigger from new process equipment.",
        "root_cause": "The change control procedure does not require requalification when tooling is replaced like for like, and nothing in the procedure lifecycle would have caught the gap.",
        "verification": "Reviewed against the last three years of tooling swaps. Two earlier swaps had also gone unqualified, neither with a detected consequence."
      }
    ],
    "escape_point": "Pull test at crimp station operation 40. It is the earliest control that should have detected an under compressed crimp and did not, because the sample plan only checked at start of shift.",
    "permanent_actions": [
      {
        "action": "Require a crimp height study and a pull test qualification after any die change, including like for like replacement, before the press returns to production",
        "addresses": "Occurrence",
        "owner": "Radu Ilies",
        "verification": "Trial on a planned die change on June 30 detected a 0.04 mm shift that the old process would have passed",
        "implemented_on": "July 2, 2026",
        "validation": "Four die changes since, all with a study on file, zero crimp height deviations at the following audit"
      },
      {
        "action": "Fit in process crimp force monitoring on the operation 40 press with automatic stop outside the window",
        "addresses": "Occurrence and detection",
        "owner": "Tomas Reiner",
        "verification": "Monitor validated by deliberately running 0.05 mm high on scrap material; the press stopped on the third piece",
        "implemented_on": "July 14, 2026",
        "validation": "Force traces retained per lot, three genuine stops since, all confirmed as real deviations"
      },
      {
        "action": "Revise the pull test sample plan to one piece per 100 with a check at every setup, break and shift change",
        "addresses": "Detection",
        "owner": "Dana Kovacs",
        "verification": "Sample plan reviewed against the June failure timeline and shown to detect the drift within one shift",
        "implemented_on": "July 6, 2026",
        "validation": "Applied since July 6, records reviewed weekly, no missed check in eight weeks"
      },
      {
        "action": "Extend the change control procedure to cover tooling replacement and add a requalification trigger",
        "addresses": "Systemic",
        "owner": "Anca Marin",
        "verification": "Draft reviewed against the two earlier unqualified swaps, both would have been caught",
        "implemented_on": "July 20, 2026",
        "validation": "PR-QMS-011 revision 4 released and briefed to maintenance and engineering, training records on file"
      }
    ],
    "prevention": [
      {
        "action": "Add die replacement as a trigger in the process FMEA and raise the detection ranking for crimp height",
        "document": "PFMEA-6620 revision 6",
        "owner": "Radu Ilies",
        "date": "July 21, 2026"
      },
      {
        "action": "Add crimp force monitoring and the revised sample plan to the control plan",
        "document": "CP-6620 revision 5",
        "owner": "Radu Ilies",
        "date": "July 21, 2026"
      },
      {
        "action": "Read across to the four other crimped assemblies on the same press family",
        "document": "Read across record RA-2026-0117",
        "owner": "Dana Kovacs",
        "date": "July 28, 2026"
      },
      {
        "action": "Add the die change requalification step to the operator and setter training matrix",
        "document": "Training matrix TM-PROD-02",
        "owner": "Sanne Kuipers",
        "date": "August 4, 2026"
      }
    ],
    "d8_closure_statement": "Containment removed on July 24, 2026 after three consecutive weeks of clean deliveries with force monitoring active. No further failures reported by the customer. Effectiveness will be reviewed again at ninety days.",
    "d8_recognition": "The team was recognised at the August plant meeting. Tomas Reiner specified and installed the force monitoring inside two weeks against a six week quote, which is the reason containment came off when it did.",
    "closed_by": "Anca Marin, Quality Manager",
    "closed_date": "August 6, 2026",
    "customer_acceptance": "Accepted by Elena Fischer, Supplier Quality, Globex Industries, on August 11, 2026, with a ninety day effectiveness review scheduled for October 22, 2026."
  }
}
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