The full 8D
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The full 8DThe full 8D
8D report - REC-2026-118 - Part AX-4420
Issued 22 August 2026, ten working days after the complaint was received.
D1 - Team: quality manager, line 3 setter, methods engineer, purchasing supporting on material.
D2 - Problem: excess play on the shaft, 14 parts out of 200 delivered, batch L-260804. Dimension measured at 12.04 mm against a tolerance of 12.00 plus or minus 0.03.
D3 - Immediate actions: 1 540 parts held, 100 percent sorting, tightened inspection over five batches. Communicated to the customer on 13 August.
D4 - Root cause: a 0.03 mm drift after a tool change carried out mid-run with no re-setting and no trial part. Three other hypotheses ruled out on evidence.
D5 - Corrective actions chosen: re-setting and a trial part become mandatory after any tool change, whatever point of the run it happens at. First-part dimension check, recorded on the sheet.
D6 - Implementation and proof: work instruction posted at the station on 20 August, four setters trained and signed off. Verified across the next three runs: no deviation, records attached.
D7 - Prevention: the control plan only called for a trial part at run start. It is amended to cover any tool change. The four other parts produced on this line are affected and have been updated.
D8 - Closure: team recognised on 22 August. This 8D stays open in the monthly review until three consecutive runs without deviation across the five parts on that line.
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