The Problem Router asks what happened, then gives the first move and the ordered path for six common quality situations, from a customer complaint to a drifting process.
PROBLEM ROUTERFREE / NO SIGNUP
What happened?
Customer complaint
Start with
Contain suspect stock before you start investigating.
Your path
- Containment
- Is / Is Not
- 8D
- PFMEA update
- Control Plan
Repeat defect
Start with
Pull the last fix and ask why it did not hold.
Your path
- Review the last fix
- 5-Why
- Fishbone
- Corrective action
- Effectiveness check
Supplier problem
Start with
Contain incoming material, then put it in writing.
Your path
- Contain incoming
- SCAR
- Scorecard
- Receiving check
- Follow-up audit
Audit finding
Start with
Restate the finding against the exact requirement.
Your path
- Requirement
- Correction
- Root cause
- CAR tracker
- Evidence
New part launch
Start with
Start the PFMEA before the Control Plan, not after.
Your path
- PFMEA
- Control Plan
- Gage R&R
- FAI
- PPAP
Process drifting
Start with
Rule out the gage before you blame the process.
Your path
- Gage R&R
- Control chart
- Capability
- Root cause
- Control Plan
All six paths
- Customer complaint: Contain suspect stock before you start investigating. Then Is / Is Not, 8D, PFMEA update, Control Plan.
- Repeat defect: Pull the last fix and ask why it did not hold. Then 5-Why, Fishbone, Corrective action, Effectiveness check.
- Supplier problem: Contain incoming material, then put it in writing. Then SCAR, Scorecard, Receiving check, Follow-up audit.
- Audit finding: Restate the finding against the exact requirement. Then Correction, Root cause, CAR tracker, Evidence.
- New part launch: Start the PFMEA before the Control Plan, not after. Then Control Plan, Gage R&R, FAI, PPAP.
- Process drifting: Rule out the gage before you blame the process. Then Control chart, Capability, Root cause, Control Plan.
The paths are a starting order, not a substitute for your customer’s requirements or your own procedures.