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8D reports that
prove it’s fixed.

Structured problem-solving for customer-facing quality issues. From team formation to permanent corrective action, every step documented.

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.
1D–2D
3D–4D
5D–6D
7D–8D

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Customer complaints triggered chaos

A key customer reported a defect. Emails flew between departments. Someone started a Word document, someone else opened a different template. Three days later, the customer asked for a status update and you were still assembling the facts.

Now every response is structured

In TeamGuru all eight disciplines live in one report, each with a due date and an approval. Containment has an owner within hours, and the customer gets a PDF report under your logo instead of an email thread.

Guided 8D workflow
PDF report under your logo
Containment assigned in hours
Every discipline dated and approved

An 8D in TeamGuru

The same reel of film, answered to the customer in eight disciplines

Norvik found PE film on 500 parts that should have been wrapped in PP. The quality alert stopped the damage on the first day. Now the customer wants an 8D: who is on it, what was contained, why it happened and what stops it for good. Here is how that report comes together in TeamGuru, from the alert to the overview of every open 8D.

  1. 1

    Start from the alert, not from a blank page

    Initiate 8D on the quality alert opens the report with the description carried over and the two documents linked. Start 8D & Inform Responsible then emails everyone who owns a discipline.

    Initiated from quality alert
    QA-0015 · PE film instead of PP on Line 4
    8D Report
    Doc No.
    8D-0092
    Title
    PE film instead of PP on Line 4
    Customer
    Norvik Automotive
    Responsibles
    L. Roberts, J. Chen, M. Turner, K. Adams
    Severity
    High
    Start 8D & Inform Responsible Email sent to 4 responsibles · 9/8, 9:15 AM
  2. 2

    Every discipline has a date

    Requested completion shows a due date for each of the eight disciplines, prefilled from your template (containment within a day, for example) or set on the report. Green is approved, red is still open. Anyone sees where the 8D stands.

    Requested completion
    1D Team 9/8
    2D Problem 9/8
    3D Containment 9/9
    4D Root cause 9/15
    5D Corrective action 9/22
    6D Validation 10/6
    7D Prevention 10/13
    8D Recognition 10/20
    ApprovedCompletedOpen
  3. 3

    Contain first, then find the real cause

    D3 lists the interim actions with target date, actual date and how effective they were. In D4 the team runs a 5-Why or an Ishikawa right in the 8D, the same tools as in RCCA, and writes down the root cause.

    3D Interim containment actions
    ActionTargetActual% Effective
    Block lots PK-4417, PK-4418 9/8 9/8 100 %
    Sort stock at Norvik 9/9 9/9 100 %
    Replacement shipment 9/9 9/10 100 %
    4D Root cause
    1. Why? 1 PE film went on Line 4 instead of PP.
    2. Why? 2 The operator took the reel that looked right.
    3. Why? 3 PE and PP reels look the same.
    4. Why? 4 Only a small label tells them apart.
    5. Why? 5 Nothing checks the film at changeover.
    Root cause summary: No check of the film type at changeover, and reels that differ only by the label.
  4. 4

    Approved, not just filled in

    When a discipline is marked completed, the responsible person approves it or sends it back, and the footer shows who and when. In a supplier 8D the supplier logs in with limited access, fills in its own actions, and you approve them.

    5D Permanent corrective action

    Barcode scan of the film is mandatory at every changeover. Wrong film, no line start.

    Completed · J. Chen · 9/22 Approve Reject
    Label PE and PP reels in different colors
    Supplier · via Partners
    Waiting for your approval
  5. 5

    Every open 8D, and how far it has got

    A report widget lists every open 8D with its progress through the eight disciplines, so management sees what is stuck without asking. Charts show open 8Ds by site and how many 8Ds you open each month.

    8D reports Update for September 2026
    Open 8D reports
    • 8D-0092 PE film instead of PP on Line 4
      Torrance
      4/8
    • 8D-0088 Mixed labels on shipping cartons
      Torrance
      6/8
    • 8D-0097 Missing torque mark on bolts
      Brno
      1/8
    ApprovedCompletedOpen
    Open 8Ds by site
    5
    3
    2
    1
    1
    Torrance Monterrey Brno Pune Suzhou
    Total 8Ds by month
    6
    9
    7
    5
    4
    Apr May Jun Jul Aug

What you get

Guided 8D workflow

Each discipline has its own guidance, fields and due date, and the responsible person approves it or sends it back. Nobody has to chase who did what.

Customer-ready reports

Export the 8D to PDF under your company's logo and send it, as an update after containment or as the final report. No copying into Word.

Timeline tracking

Every discipline shows its due date, who completed it and who approved it, and when. Overdue disciplines turn red, so you see where the 8D is stuck.

Recurrence prevention

Discipline 7 specifically addresses systemic changes to prevent the problem from happening again, anywhere in the organization.

Presenting this to your team or management?

Download a two-page overview of the 8D Reports module to share or print.

Download PDF

Common questions

Do we have to complete all eight disciplines? +
Your template decides what each discipline asks for: headings, guidance, fields, tables, attachments, actions, 5-Why or Ishikawa. Each discipline has its own due date and is approved on its own.
Can customers see the 8D report while it is in progress? +
You decide when the customer gets it. Export the 8D to PDF under your company's logo at any point: an interim update after containment, the final report once every discipline is approved.
How long does a typical 8D take to complete? +
That is up to you and your customer. Every discipline has a due date, prefilled from your template (containment within 24 hours, for example) or set on the report, and the report shows which disciplines are approved, done or overdue.
Can a supplier fill in its own 8D? +
Yes. In a supplier 8D you make the supplier responsible for the actions. They log in with limited access through Partners, fill them in, and you approve each discipline.
Can the 8D follow our customer's form (VDA or customer-specific)? +
Yes. The 8D is a template you shape: discipline headings, guidance, fields and due dates can follow your customer's 8D form, VDA or your own.

See 8D Reports in action

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