8D Report Builder

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Review all disciplines below. Switch to Edit to update the report.

Overview ↗

Report header

Report title

Incorrect shipping label detected at customer — Line 2 pack-out

Case / SCAR / NC number

SCAR-2026-0142 (example)

Champion / owner

Quality manager (example)

Report date

April 2026

Site / customer (optional)

Plant 3 — automotive OEM programme

D0 — Prepare and plan

Customer notified wrong SKU label on a pallet (2 of 120 cartons). Risk: wrong part at assembly. Team chartered same day; containment goal: no further suspect material ships. Target closure: 45 days per customer SCAR.

D1 — Establish the team

#	Team member	Role
1	Quality manager (example)	Champion
2	Pack-out lead	Core team
3	Maintenance technician	SME — equipment
4	Production planner	Core team
5	Logistics coordinator	Core team
6	Customer quality representative	Customer liaison

Meeting cadence & notes

Daily 15-minute stand-up until containment verified; weekly management review with metric review.

D2 — Describe the problem

What: Outer label shows SKU-B; inner cartons are SKU-A. Where: Line 2 pack-out, pallet P-4401, despatch dock 12. When: Found at customer inbound 08 Apr; suspect lots 01–07 Apr. How many: 120 cartons in lot; 2 mis-labelled found; 100% sort at customer pending. IS / IS NOT: Only Line 2 after morning changeover; other lines and suppliers not involved.

D3 — Interim containment actions

#	Action	Owner	Due	Status
1	Hold all finished goods from Line 2 back to last known-good label verification (03 Apr 06:00).	QA + logistics	Day 1	Complete
2	100% label audit on WIP and FG; block shipment until QA sign-off.	Pack-out lead	Day 1–2	Complete
3	Notify downstream warehouses to quarantine same lot codes.	Logistics	Day 1	Complete

Effectiveness check

Zero additional escapes in first 72 hours of inspection; quarantine effectiveness confirmed.

D4 — Define and verify root cause(s)

Analysis approach

5 Whys with pack and maintenance; review of verifier fault logs; line observation during changeover; comparison to Line 1 (no bypass).

Verified root cause(s)

Barcode verifier bypassed after changeover when operator cleared fault without supervisor reset — procedure gap. Contributing: no interlock between verifier fault state and line run signal; changeover checklist omitted verifier test card.

Escape point & why it was missed

Escape at final pack station. Missed internally because bypass did not alarm to QA and post-changeover checks were not mandatory.

Verification of root cause

Forced-fault trials reproduced condition; interlock pilot prevented line start when verifier in fault — confirmed with 20 trials.

D5 — Choose and verify permanent corrective actions

#	Action	Owner	Due	Status
1	Software interlock — line cannot run with verifier in fault.	Engineering + IT	Week 4	Implemented
2	Digital checklist: test card at shift start and after each changeover.	Pack supervisor	Week 3	Implemented
3	Dual scan — carton + pallet at apply station.	Engineering	Week 5	Implemented

Validation summary

200 consecutive packs on trial lots with forced-fault tests passed; customer witnessed validation run.

D6 — Implement permanent corrective actions

Implemented in week 5; all shifts trained; old procedure red-lined. Customer witnessed validation run; 30-day production monitor: 0 label mismatches, verifier forced-stop tests 100% effective.

D7 — Prevent recurrence

Update control plan and layered process audits. Mirror interlock on Line 1 (similar cell). Add PM for verifier firmware. Share lesson in monthly quality council; supplier communication where labels are pre-printed.

D8 — Recognise the team

Team recognised by plant manager; SCAR closed with customer. Lesson: treat verifier like safety-critical — interlocks beat reminders. Yokoten checklist added to new equipment buy guide.

Report header

Report title

Case / SCAR / NC number

Champion / owner

Report date

Site / customer (optional)

D0 — Prepare and plan

Symptom, urgency, scope, and how you will run the 8D (resources, milestones).

D1 — Establish the team

One row per person. Role examples: Champion, Core team, SME, Customer liaison.

#	Member	Role
1
2
3
4
5
6

Meeting cadence & notes

D2 — Describe the problem

Facts: what, where, when, how many, IS / IS NOT. Quantify the gap vs requirement.

D3 — Interim containment actions

Table of containment tasks; add rows as needed.

#	Action	Owner	Due	Status
1	Hold all finished goods from Line 2 back to last known-good label verification (03 Apr 06:00).
2	100% label audit on WIP and FG; block shipment until QA sign-off.
3	Notify downstream warehouses to quarantine same lot codes.

Effectiveness check

D4 — Define and verify root cause(s)

Use the sections below instead of one long paragraph.

Analysis approach

Methods used: 5 Whys, fishbone, comparative tests, data review, etc.

Verified root cause(s)

State the cause(s) supported by evidence — not guesses.

Escape point & why it was missed

Where the defect escaped the process and which controls failed or were absent.

Verification of root cause

How you proved this cause (trial, demonstration, data).

D5 — Choose and verify permanent corrective actions

Permanent actions table; validation narrative below.

#	Action	Owner	Due	Status
1	Software interlock — line cannot run with verifier in fault.
2	Digital checklist: test card at shift start and after each changeover.
3	Dual scan — carton + pallet at apply station.

Validation summary

D6 — Implement permanent corrective actions

Deployment, training, tracking dates, and evidence the problem stays solved.

D7 — Prevent recurrence

Update standards, FMEA/control plan, audits, systemic fixes across similar lines/sites.

D8 — Recognise the team

What went well, lessons learned, recognition, and closure of the case.

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8D Report Builder — Example

8D Report Builder