Drill Deep Worksheet
Name: Phone: Revision Date:
Supplier contact:
GM SQE:
Supplier Duns: Supplier Name and Location:
Issue Title:
ID Type: PRR PRTS CDP Other ID Number:
Failure Mode:
Effects of Failure Mode:
Cause of Failure Mode:
5 Whys Corrective Action Owner Due Date
M1
Why did the manufacturing process
not prevent this failure mode?
M2
***************
*************** M3
****
Prevent
***************
*************** M4
****
Manufacturing process -
***************prevention &
***************
standardized work M5
****
***************
*************** M-RC
****
Q1
Why did the quality process not
protect GM from this failure mode?
Q2
***************
*************** Q3
****
Protect
***************
*************** Q4
**** Qualit y process -
*************** detect ion &
*************** cont ainm ent Q5 .
****
***************
*************** Q-RC
****
P1
Why did the planning process not
predict this failure mode?
P2
***************
*************** P3
****
***************Predict
*************** P4
**** Planning process -
inform a tional cont ent
***************
***************
in FMEAs and CPs P5
****
***************
*************** P-RC
****
K1
What are the key findings based on
this quality issue?
K2
***************
*************** K3
****
***************
*************** K4
****
***************
*************** K5
****
GM1927-84 Drill Deep Worksheet Rev. 7.6 10/12/04
DRAFT
Drill Deep Worksheet
Name: Phone: Revision Date:
Supplier contact: J. Smith 248-555-5555 02/24/04
GM SQE: T. Smith 248-555-5555
Supplier Duns: 9198213232 Supplier Name and Location: Supplier XYZ, Pontiac, MI USA
Issue Title: End cap not fully seated into window on valve.
ID Type: PRR PRTS CDP Other ID Number: 30011223-989898
Failure Mode: End cap not fully seated into window of valve.
Effects of Failure Mode: Loose parts found in Product XYZ fuel tanks.
Cause of Failure Mode: Positive stops were not adjusted correctly for the new, low permeation family insert causing the cylinder did not travel to full insertion.
5 Whys Corrective Action Owner Due Date
Positive stops were not adjusted correctly for
Validate correct position of stops and
the new, low permeation family insert
M1 a PM plan to be developed to ensure J. Smith 03/15/04
causing the cylinder did not travel to full
location of stops.
Why did the manufacturing process insertion.
not prevent this failure mode? Control Plan was not updated to indicate
M2
recalibration for new family insert.
***************
Manufacturing was not aware of a new
*************** M3
**** family insert.
Prevent
*************** Poor communication between Product
*************** M4 Development & Manufacturing on design
****
Manufacturing process - change.
prevention &
***************
standardized work
*************** M5
****
*************** Develop training plan for employees
Supplier XYZ Launch Planning System was
*************** M-RC and implement a layered audit of J. Smith 03/31/04
**** not followed.
planning process.
No detection error-proofing for "end cap fully
Q1
Why did the quality process not seated".
protect GM from this failure mode?
Q2
***************
*************** Q3
****
Prot ect
***************
*************** Q4
**** Qu ality process -
*************** det ection &
***************con tainment Q5
****
*************** Re-evaluate prevention error-
False sense of security in error proofing
*************** Q-RC proofing process and implement J. Smith 03/15/04
**** prevention of positive stops in tooling.
detection error-proofing process.
RPN number was not determined properly in
P1
Why did the planning process not PFMEA.
predict this failure mode? Occurrence and detection ratings were not
P2
determined properly.
***************
*************** P3
****
Predict
***************
*************** P4
**** Plan ning process -
inform at ional content
***************
***************
in FMEAs an d CPs P5
****
*************** FMEA training plan to be developed
Inadequate knowledge of FMEA
*************** P-RC and monthly FMEA layered audit J. Smith 03/15/04
**** methodology.
review to be implemented.
Develop regular change control
K1 Engineering change management execution. J. Smith 03/15/04
meetings with entire team.
What are the key findings based on
this quality issue?
Develop Supplier Change Request
K2 PPAP / PTR execution. J. Smith 03/15/04
audit process.
*************** Re-evaluate prevention error-
Insufficient error-proofing incorporated into
*************** K3 proofing process and implement J. Smith 03/15/04
**** valve assembly.
detection error-proofing process.
*************** FMEA training plan to be developed
Inadequate knowledge of FMEA
*************** K4 and monthly FMEA layered audit J. Smith 03/15/04
**** methodology.
review to be implemented.
***************
*************** K5
****
GM1927-84 DRAFT 10/12/04
Drill Deep Worksheet Rev. 7.6
