Quality Management
Stop firefighting,
start preventing.
Catch issues early, find the root cause, close the loop. One system for alerts, RCCA, 8D, and audit-ready compliance.
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What powers Quality Management
1. Quality Alerts
Catch issues before they spread
Instant alerts notify the right people and containment actions are assigned immediately.
PE film instead of PP on Line 4 Initiate RCCA Initiate 8D Open Closed
Doc No. QA-0015
Reject Type Wrong material
Severity High
Leader Lisa Roberts
Qty Defective 500
Cost (COPQ) $18,400
Customer Norvik Automotive
Problem Description
PE film used instead of PP on Line 4. The reels look the same; the label is the only difference.
Stock Hold Actions
Block lots PK-4417, PK-4418. Quarantine B3. No shipping under deviation.
Field Actions Management
Sort stock at Norvik, replace from safety stock.
Whom To Inform
LR L. Roberts
JC J. Chen
MT M. Turner
Send Alert Notification Notification sent
Corrective / Preventive Actions 0 of 31 of 32 of 33 of 3
Block lots PK-4417 and PK-4418 9/8 LR Sort stock at the customer 9/9 JC Scan the film barcode at changeover 9/12 MT
2. Root Cause Analysis
Dig deeper to understand why it happened
Fishbone diagrams and 5-Why analysis guide your team to the true root cause.
PE film instead of PP on Line 4 Open Closed
Doc No. RCCA-0042
Source QA-0015
Priority High
Leader Sarah Mitchell
Due Nov 30, 2026
Product PP Laminate Film
Problem Description
PE film used instead of PP laminate on Line 4. 500 units affected across Lots #PK-4417 and #PK-4418.
Fishbone Analysis
5-Why Analysis
1
PE film on Line 4? The operator took the reel that looked right.
2
Why that reel? PE and PP reels look the same.
3
Look the same? Only a small label tells them apart.
4
Not caught? Nothing checks the film at changeover.
5
No check? The changeover standard never asked for one.
Root Cause
No check of the film type at changeover, and reels that differ only by the label.
Corrective Action
Barcode scan of the film at changeover, Line 4. Lots PK-4417 / PK-4418 quarantined.
Preventive Action
Film check in the changeover standard. Color-coded PE and PP reels from the supplier.
3. 8D Reports
Prove the issue is contained and will not recur
Guided 8D with approval of each discipline and a PDF export for your customer.
8D: PE film instead of PP on Line 4 Export PDF Open Closed
Doc No. 8D-0092
Source QA-0015
Severity High
Leader Lisa Roberts
Due 10/6/2026
Customer Norvik Automotive
1D Team
L. Roberts (Quality), J. Chen (Production), M. Turner (Maintenance), K. Adams (Logistics)
2D Problem
500 parts shipped to Norvik in PE film instead of PP. Lots PK-4417, PK-4418.
3D Containment
Lots blocked, stock sorted at Norvik, replacement shipped. 100% effective.
4D Root Cause
5-Why: the PE and PP reels look the same and nothing checks the film at changeover.
5D Permanent Correction
Barcode scan of the film is mandatory at every changeover.
6D Validation
30 days on Lines 3–6 with zero mix-ups. Work instruction updated.
7D System Prevention
PFMEA and control plan updated. The supplier labels PE and PP reels by color.
8D Recognition
Team thanked at the plant meeting. Scan rolled out to all packing lines.
All 8 disciplines approved. PDF sent to Norvik.
4. Document Control
Capture what you learned
Update SOPs while the knowledge is fresh. Version control, approvals, and auto-distribution.
Supplier Qualification Procedure Approved Draft
Doc No.DOC-0042
ResponsibleJ. Taylor
TypeProcedure
Version3
1. Scope
This procedure defines the requirements for qualifying new suppliers and requalifying existing ones. It covers initial assessment, on-site audit checklists, and RCCA follow-up for non-conformances.
2. Initial Assessment
Evaluate supplier capability using the standard qualification checklist. Score each category (quality system, capacity, delivery). Minimum passing score: 75%.
3. On-Site Audit
Conduct facility audit using Form AUD-12. Verify process controls, measurement systems, and material traceability. Document findings and assign corrective actions for any gaps identified during the audit.
4. Corrective Actions
Non-conformances found during qualification require formal RCCA. Suppliers must submit root cause analysis and corrective action plan within 10 business days.
Approval
| JT J. Taylor | Pending |
| RB R. Bennett | Pending |
Informed Employees
| Name | Status |
|---|---|
| SM S. Mitchell | Sent Read |
| JC J. Chen | Sent Read |
| LR L. Roberts | Sent Read |
| KW K. Walker | Sent Read |
| DH D. Harris | Sent Read |
5. Checklists & Audits
Lock it into the process
Every round follows the same checklist, and a fresh copy is ready on schedule.
Checklist: New Supplier Qualification In Progress Complete
Doc No. CH-0087
Type Supplier qualification
Location Plant A
Leader Sarah Mitchell
Approver Pam Adamcik
Created Jun 25, 2025
Actions 0 of 7 2 of 7 4 of 7 6 of 7 7 of 7
Action Owner Due
Define quality requirements S. Mitchell Jul 1 SM
Review supplier capability report P. Adamcik Jul 4 PA
Approve control plan J. Chen Jul 8 JC
First article inspection (FAI) L. Roberts Jul 11 LR
Process validation (PPAP) S. Mitchell Jul 18 SM
Update incoming inspection SOP J. Chen Jul 22 JC
Release to production P. Adamcik Jul 25 PA
All actions completed. Supplier qualified for production.
6. Quality KPIs
Track performance so you never slip back
KPI dashboards track quality metrics, and AI insights flag anomalies before they turn into a trend.
KPI Dashboard: Quality Performance This month ‹ ›
Plant Yield %PPMScrap k$COPQ k$Complaints
Torrance, CA 98.0 ↑ 232 ↑ 85 ↓ 142 ↓ 3 →
Greenville, SC 98.0 ↑ 220 ↑ 100 ↑ 168 ↑ 1 ↓
Saltillo, MX 97.8 → 168 ↑ 103 ↑ 195 ↑ 4 ↑
Kansas City, MO 96.7 ↓ 220 ↑ 100 ↑ 156 → 2 ↓
Lansing, MI 98.0 ↑ 0 ↑ 92 ↓ 210 ↓ 5 ↑
Best Yield
Torrance · 98.0%
Lowest PPM
Lansing · 0
Lowest COPQ
Torrance · $142k
Top Alert
Lansing · 5
AI Insights Past 3 months
Lansing scrap cost spiking
Scrap at Lansing dropped to $92k but shows high volatility. The packaging material incident on Line 4 contributed $18k in Q4. Monitor changeover controls.
Kansas City yield declining
Process yield fell from 97.5% to 96.7% over 3 months. Pattern correlates with supplier changeover on PP laminate film. Recommend audit.
Greenville improving steadily
All 4 metrics trending up. New barcode verification at changeover (from 8D-0092) eliminated material mix-ups since implementation.
How quality teams use TeamGuru
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Frequently asked questions
How fast can we get started with Quality?
Quality alerts and RCCA workflows can be live in under 2 weeks. Full 8D and checklist setup typically takes 3–4 weeks with our team's help.
Does TeamGuru support IATF 16949 and ISO 9001?
Yes. TeamGuru is built for regulated environments. Customers use it to manage audit-ready documentation, corrective actions, and compliance checklists.
Can we use Quality alongside our existing QMS?
Absolutely. Many teams start by adding TeamGuru's quality alerts and RCCA on top of their current system, then gradually consolidate.
How does the 8D report workflow work?
When a quality issue is raised, TeamGuru guides your team through all 8 disciplines — from team formation to root cause to verification — with deadlines and accountability at every step.
Is there a free trial?
Yes, a free 14-day guided trial on one of your quality processes, with your own data if you want. Book a demo and we'll set it up.