194110099.

xls

QRCM Summary
Trac$in" %o. &ate '#ened (ast u#dated)

QRCM Problem Solving Report

D0 - Customer Reported problem:
&ate Re#orted) Customer %ame) Meritor P+%) Qty Re*ected) Customer Contact) Customer P+%) %ame ,unction Phone

Customer Re*ect %o. Phone %o.

D1 - Team
Role Cham#ion (eader Mem er Mem er Email

D2A - Problem Statement D2 - Problem Des!ription

-rie. Pro lem &escri#tion /hat) /here) /hen) 0ow i")

D" - Containment A!tion#s$

%o. 1ction &escri#tion

Res#

&ate !nitiated Com#

2eri.ication 3Methods and Results4

D%A - &!!ur root !ause

2eri.ication 3Methods and Results4 &ate 2eri.ied)

D%

- 's!ape Root Cause

&ate 2eri.ied)

2eri.ication 3Methods and Results4

D()D* - Permanent !orre!tive a!tions #o!!ur and es!ape$

%o. 1ction &escri#tion

Res#
Tar"et

&ate Com#

2alidation 3Methods and Results4

D+ - Preventive A!tions
%o. 1ction &escri#tion

Res#
Tar"et

&ate Com#

2alidation 3Methods and Results4

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194110099.xls

QRCM Summary

D, - Team) -ndividual Re!ognition . Approval

Approval: #ele!troni! approval is a!!eptable i/ 0ept as re!ord atta!1ed to t1e ,D summar2$

Signature 3ame Title Quality (ead '#erations (ead Date

!. a##lica le !. additional si"natures re5uired !. additional si"natures re5uired !. additional si"natures re5uired

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1ction Plan

A!tion Plan Summar2

Tra!0ing 4: Sub7e!t:
3umber -ssue ) A!tion -tem

C1ampion: 8pdated:
Target Completion Date

5 6 R

- Complete - 3eeds Attention - 3eeds 8rgent Attention

Start Date:
Responsible

Status A!tion Status ) Results

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194110099.xls

1ction Plan

A!tion Plan Summar2

Tra!0ing 4: Sub7e!t:
3umber -ssue ) A!tion -tem

C1ampion: 8pdated:
Target Completion Date

5 6 R

- Complete - 3eeds Attention - 3eeds 8rgent Attention

Start Date:
Responsible

Status A!tion Status ) Results

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194110099.xls

1lert

Q8A9-T6 A9'RT
Tra!0ing 3o: Part 3o):amil2 A//e!ted: Customer: Con!ern Des!ription Date -nitiated: Date e;pires: -ssued b2:

5ood Part

ad Part

Pi!ture< s0et!1 or des!ription

Pi!ture< s0et!1 or des!ription

C&3TA-3M'3T R'Q8-R'M'3TS
3&= 9&CAT-&3 A3D)&R PR&C'SS P&-3T D'SCR-PT-&3 &: SP'C-A9 ACT-&3S START R'SP= DAT')T-M'

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194110099.xls

Containment &ata

CONTAINMENT CHART
Tracking No. Date Initiated

Please follow the q alit! alert for contain"ent criteria

('C1T!'% RESP'%S!-!(!T6 &1TE S0!,T 7 Customer !n transit to Customer Su##lier !ns#ected Re*ected !ns#ected Re*ected !ns#ected Re*ected !n transit .rom su##lier !n #lant location 1 !n #lant location 8 !n #lant location 9 !n #lant location 4 !ns#ected Re*ected !ns#ected Re*ected !ns#ected Re*ected !ns#ected Re*ected !ns#ected

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194110099.xls !n #lant location 4

Containment &ata Re*ected

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194110099.xls

:;why

(->?6 A3A96S-S
Problem Statement:

>12 e!ause t1e >12 e!ause t1e >12 e!ause t1e >12 e!ause t1e

Predi!t - >12 did t1e planning pro!ess not predi!t t1e non!on/orman!e@

>12 e!ause t1e >12 e!ause t1e >12 e!ause t1e >12 e!ause t1e

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194110099.xls

:;why

(->?6 A3A96S-S
Problem Statement: Prevent - >12 did t1e manu/a!turing pro!ess not prevent t1e non!on/orman!e@

>12 e!ause t1e >12 e!ause t1e >12 e!ause t1e >12 e!ause t1e

Prote!t - >12 did t1e Aualit2 pro!ess not prote!t /rom t1e non!on/orman!e@

>12 e!ause t1e >12 e!ause t1e >12 e!ause t1e >12 e!ause t1e

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!s;!s %ot

Problem Statement: Problem Des!ription: 9ast 8pdated:

-s

-s 3ot

5et -n/ormation

Di//eren!es

C1anges

>?AT
/hat o *ect has de.ect= 3#art + .amily name4 /hat o *ect has de.ect 3#art num er4 /hat #ortion o. the o<erall o *ect has the de.ect 3s#eci.ic com#onent i. you are descri in" a lar"e system or assem ly44 /hat de<iation a"ainst what s#ec.

>?'R'
/here the concern is on the o *ect 3 e s#eci.ic ; (0+R0? inside+'utside? to#+ ottom? .ront+rear? location? which end? scatter or concentration dia"ram4 /here is the concern on the <ehicle= 3(0+R0? .ront+rear? side to side? to#+ ottom? 1t what #lace in the #rocess the de.ect is .irst identi.ied= 3exact location in their #rocess ; exact #rocess ste#4 /here seen= ; 3s#eci.ic location4 /here seen ; "eo"ra#hical location ; #lease e as s#eci.ic as #ossi le

>?'3
/hen was the #ro lem initially re#orted= 3date? time4 /hen was the #ro lem .irst ex#erienced + o ser<ed 3date o#erator? machine4 /hen else this #ro lem was seen 3i. multi#le occurrence? then attach a detailed s#readsheet in the wor$ oo$ and narrate oo$;ends here4

/hen in the li.ecycle the #ro lem has occurred= 3years in ser<ice? milea"e? etc.

?&> -5
&escri e si@e o. the #ro lem on an indi<idual com#onent4 ; ma"nitude? si@e? s#read 3how much o. each #art a..ected4? se<erity? #enetration? etc. ; !. data are not 100> .actual? actions are to e de.ined to "et .acts4 %um er o. #ro lems on each #art or indi<idual assem ly %um er o. #ro lem on each indi<idual customer assem lies Total num er o. com#onents a..ected

> o. #roduct or "rou# a..ected

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0y#othesis &e<elo#ment

PR& 9'M S&9B-35 >&RCS?''T

9ist C1ange ?oD T1eories di..erence or chan"e statement 3.act4B how 3en"ineerin" rationale4 C #ro lem statement
1

Probabilit2

0 0 0 0 0 0 0 0 0

C & E , A 0 !

Clic$ to RunMacro to D#date Trial Run o. Possi le Causes

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194110099.xls

Clic$ to RunMacro to D#date Trial Run o. Possi le Causes

0y#othesis &e<elo#ment

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194110099.xls

0y#othesis &e<elo#ment

PR& 9'M S&9B-35 >&RCS?''T

Trial Run o/ Possible Causes

-s Statement
1

T1eor2 EAE e;plains t1e E-sE statement@ True or :alse

8 9 4 : E F G 9 10 11 18

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194110099.xls

0y#othesis &e<elo#ment

19 14 1: 1E 1F 1G 19 80 81 88 89 84 8: 8E 8F

T&TA9

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194110099.xls

0y#othesis &e<elo#ment

T1eor2 E E e;plains t1e E-sE statement@ True or :alse

T1eor2 ECE e;plains t1e E-sE statement@ True or :alse

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

T1eor2 EDE e;plains t1e E-sE statement@ True or :alse

T1eor2 E'E e;plains t1e E-sE statement@ True or :alse

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

T1eor2 E:E e;plains t1e E-sE statement@ True or :alse

T1eor2 E5E e;plains t1e E-sE statement@ True or :alse

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

T1eor2 E?E e;plains t1e E-sE statement@ True or :alse

T1eor2 E-E e;plains t1e E-sE statement@ True or :alse

This document is Electronically Controlled in the Policies and Procedures we site on !ma"ine. Printed co#ies are considered uncontrolled.

194110099.xls

0y#othesis &e<elo#ment

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Cause and Effect Diagram

Measurement Materials Method

Problem Statement

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Environment

Manpower

Machine

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DETERMININ# $%$TEM INADE&'AC% RE$PON$I()E *OR H'MAN ERROR

'as support provided to perform tas"$ Personnel Equipment Material Supplies Services / facilities Yes No $'PPORT *AI)ED No 'as type / capa(ility / amount / condition of support provided sufficient to correctly perform the tas"$

Yes

$ ,,ort not res,onsi-le

No Do standards / procedures e)ist for the tas"$

$TANDARD *AI)ED No Are they clear / practical

Yes

Yes

$tandards . ,roced res not res,onsi-le

No

TRAININ# *AI)ED No 'as trainin* correct+ complete+ and sufficient for performance to standard$

H'MAN ERROR

Did individual receive trainin* on ho& to perform the tas"$

Yes

Yes

Training not res,onsi-le

No

)EADER *AI)ED No Did Leader(s ! Ma"e on#the spot corrections$ Emphasi,e (y the (oo" e)amples and opportunities$ %a"e action &hen appropriate$

Yes Did leader(s enforce standards$

Yes

)eader not res,onsi-le

INDI+ID'A) *AI)ED

Did individual "no& standards and &as he trained on standards$

Yes

Yes Did individual elect not to follo& the standard (self#discipline $ (Attitude+ haste+ overconfidence+ self#induced fati*ue

No

Indi/id al not res,onsi-le

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194110099.xls

9x:

" ; ( >or0s1eet
: /hys /hy did the #lannin" #rocess not #redict the non;con.ormance= P1 P8 P9 P4 Planning process informational content in FMEAs and CPs P: P;RC M1 M8 M9 M4 M: M;RC Q1 Q8 Q9 Q4 Q: Q;RC /hat are the $ey .indin"s ased on this 5uality issue and the a o<e : /hy analysis= H1 H8 H9 H4 H: Correcti<e 1ction 'wner &ue &ate

Predict

/hy did the manu.acturin" #rocess not #re<ent the non;con.ormance=

Prevent
Manufacturing process standardized work and error proofing

/hy did the 5uality #rocess not #rotect .rom the non;con.ormance=

Protect
Quality process detection & responsiveness

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194110099.xls

" ; ( Matri; . Read A!ross

,D Tra!0ing 3o= Date &pened: Date 9ast 8pdated: & F 3)A
3ot Appli!able

Read;1cross Matrix

Meritor Division Meritor 9o!ation Meritor Produ!t

&riginal Produ!t 9ine and 9o!ation Produ!t 9ine and 9o!ation Dit1 Similar Pro!ess

Complete and "rd part2 ) Beri/ied Complete . Supplier Beri/ied &nl2 3ot Completed

PR'D-CT
Why did the planning process not predict the nonconformance?

Document Verification/ Validation

PR'B'3T
Why did the manufacturing process not prevent the nonconformance?
Document Verification/ Validation

PR&T'CT
Why did the quality process not protect the customer from the nonconformance

Document Verification/ Validation

Ce2 :indings
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>it1 in

S2stemi! -ssue ( >12@

S2stemi! Root Cause #RC$

S2stemi! C1ampion Due Date Corre!tive A!tions

Plan

" Plan t

Plan t

Plan t

Plan t