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IS - IS NOT / COMPARITIVE ANALYSIS motivates deliberate thinking about the Boundaries of What Is or Is Not.

WHATObject / Deviation

WHERESeen on Product / Process

WHENFirst seen / Last Reported

HOW BIGHow many objects / Defects

COVER PAGE

D2 – Fill in the data for the ‘WHAT’ section accordingly

WHAT section

HelpWhat object has the Defect?Auto Input from Problem Workbook

HelpWhat similar object(s) could have the Defect

HelpCONSIDER Part NumbersShop Floor DescriptionsCustomer Descriptions

HelpWhat is the Defect?Auto Input from Problem Workbook

HelpWhat other Defects “could” have been observed?

HelpWhat has changed In / and / aroundthis difference?

HelpDate change was reversed. If still same ? Enter “current”

HelpHow could these Differences or Changes have Created or Causedthe Problem – as it is defined?

Other Similar Valves

Major Leak

Data to confirm Problem has not previously occurred on similar Parts

HelpWhat could CAUSE the Difference between the IS Compared to the IS NOT?

Different Operating Conditions

Higher Operating Pressure

Seal introduced to cope with increased pressure

HelpCONSIDER How could the “changes” Have CAUSED the “differences”

Used only by TooGood Motor Corporation

Current

D2 – Fill in the data for the ‘WHERE’ section accordingly

WHERE section

HelpWhere specifically on the object does the Defect occur?

HelpWhere in the Process Flow is the Defect seen

HelpWhere specifically on the object does the Defect occur?

HelpWhere could the Defect have been observed?

HelpCONSIDEREnvironmental factorsContaminationPossible Abuse

HelpWhat could CAUSE the Difference between the IS compared to the IS NOT?

HelpCONSIDERHow could the “changes” have CAUSED the “differences”

HelpWhat has changed In / and / aroundthis difference?

HelpHow could these Differences or Changes have Created or Caused the Problem – as it is defined?

At other Joints

On the Pressure Test

Validate Leakage in Field

Vibration of Valve

Loss of Torque on Union

Used in Potentially harsh Operating Conditions

Vibration could weaken Torque on Union

Around Sealing Washer

When Vehicle is in the Field

D2 – Fill in the data for the ‘WHEN’ section accordingly

WHEN section

HelpWhat has changed In / and / aroundthis difference?

09-Feb-11

02-April-12

After three months of use

Before 27-Mar-12

During Product/Vehicle Testing

Validate Service History

Product Cycle Time Loss of Torque

Seal Surface deteriorates

Valve was subject to Operating Conditions and Seal possibly “settled in”

Vibration could weaken Torque on Union

HelpWhen in time was the Defect first observed?

HelpWhen was it Seen But NOT Reported

HelpWhen in time “could the Defect have been observed?

HelpWhere “should” the Defect have been seen, but wasn’t.

HelpCONSIDERMode of OperationModifications/ChangesReliability Data

HelpWhat could CAUSE the Difference between the IS compared to the IS NOT?

HelpCONSIDERHow could the “changes” have CAUSED the “differences”

HelpHow could these Differences or Changes have Created or Caused the Problem – as it is defined?

HelpWhen since that time has it been seen?

HelpConsider changes in the Process Cycle.

HOW BIG section

D2 – Fill in the data for the ‘HOW BIG’ section accordingly

HelpWhat has changed In / and / aroundthis difference?

HelpHow many units, items, objects, have the defect? Use % or how many out of?

HelpIs the Problem getting Bigger/ Stable / Smaller?

HelpHow often “could” the Defect occur

HelpCould the Problem be worse or better without intervention?

HelpCONSIDERWarranty ReturnsQuality RecordsCP / Cpk

HelpWhat could CAUSE the Difference between the IS compared to the IS NOT?

HelpHow could these Differences or Changes have Created or Caused the Problem – as it is defined?

HelpHow many Defects per Object, Part or Unit?

HelpCONSIDERHow could the “changes” have CAUSED the “differences”

One

8 from 40,000 units

Erratic

On 39,992 units

Multiple Leaks

Predictable

Investigate “unreported” instances from routine Servicing

Interpretation of extent of Leakage

Operational Use

Different Service Outlets Different Service Outlets

HelpHow many objects “could” have had the Defect?

Problem Solving I nnovatorSolving Tomorrows Problems Today

This completes theD2 Comparative Analysis

Now start the Flow Chart