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1

US-QS4-002

Corrective Action Report (8D)
Initiation date:

4/25/2023

Customer Nonconformance

Prevention

8D Tracking #:

Internal Nonconformance

Supplier Performance

QN #:

Supplier Nonconformance

Environmental Nonconformance

Audit Nonconformance

Safety Nonconformance

(if applicable)

8D Last Updated:

8D Status:
Open

Supplier Information

Blue Bird Plant
Location:
Customer Code:

Cost Center:

Fort Valley, GA
1123

Cummins RMEP
1123

Location:
Supplier Code:

Days 8D open:
9

1st response within 24 hours of Notification - Identify solution within 5 days Verify Corrective Action within 15 days.
Step

1 -Team
Establish the team

1

2 -Describe
Problem description

3 -Contain
Temporary action /
containment

Please Submit 8D's to SQE or QSE
4 -Diagnose
5 -Solve
Root cause analysis

6 -Validate

Identify Permanent
Corrective Actions (PCA)

Verification of
Permanent Corrective
Actions (PCA)

7 -Prevent
Prevention of
recurrence

8 -Wrap
Congratulate the team

Establish the team - The team should consist of people with process/product knowledge, problem solving skills and authority to implement corrective
actions.

Role
System manager/
Team Leader
Team member

additional
Team members

2A

Name

Title
RMEP Quality Director
CQA Quality Engineer
Quality Inspection Manager
Manufacturing Project-Training
CQA tech
Manufacturing Engineer
Plant Customer Quality Business Leader
Operations Manager
Operations Manager
Operations Manager

Phone

E-Mail

Describe the Problem: Loose bottom lifting bracket screw at the customer site leading to the engine falling off and causing safety issue while lifting the
engine.

Part Description (product type, etc.)
Lifting Bracket capscrew (LA 9172 option)

Problem Description - What?, Where?, When?, Who?, How many?

Part Number(s)
3903990

Customer(s) and Model Year
B6.7 300 HP-2023

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US-QS4-002

1. What: Lifting bracket capscrew loose causing near mis at Blue Bird Bus, Plant
2. When: April, 13, 2023
3. Where:Blue Bird Bus Plant, Fort Valley, GA
4. How Many: 5 (3 engine found at Blue Bird and 2 engine found in the warehouse)
5. Affected Plant: Blue Bird

Insert Picture (1)

Insert Picture (2)

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3

US-QS4-002

Interim Containment Actions - Temporary actions to contain or fix the problem at the supplier and/or customer location until permanent

corrective

action is implemented. Describe any part containment activities that took place (customer, supplier, ...) if applicable

Containment Activities - identify action items in the list below
#

Interim Containment Action

Containment
location

Responsibility

1

Suspect engine list sent to Blue Bird. Blue Sky performed engine sorting at
Warehouse. 93 engines sorted 2 defects
CLICKfound
TO OPEN

at customer

2

Station 5800 identified as the perfect spot for the tohnichi overcheck. MCR
CLICK(For
TO over
OPEN
routing for approvals. RMEP-0423-95. ESNF 99102368
checking)

3

Added checks at station 650 to look for any cap screw standing proud. ESNF
99101216

Planned

Actual

(Date)

(Date)

Blue Sky

4/14/2023

4/15/2023

completed

RMEP

ME

4/13/2023

4/14/2023

completed

RMEP

ME

4/14/2023

4/15/2023

completed

Status

4

SORTING ACTIVITIES
Location

# of pieces sorted

# of pieces defective

YFAI: Warehouse

93

2

% Defective

Responsibility
Blue Sky

Clean Point at Customer:

Clean Point at plant/location:

Clean Point at Supplier:

ESN 99101216

ESNF 99102368

N/A

4A Diagnose Root Cause (Pending) FTA in progress
Brainstorm the possible causes of the problem
Root Cause Occurence root causes
1. Technical- Uncertified operator working at Station 4680 (station critical since it has safety related parts)
2. Systemic- No process in place to communicate and have a deviation signoff for approval and an interim training conducted for the uncertified operators running the station.
Non-detection root causes
1.Technical- No visual/torque overcheck inspection in place downstream after the installation of the rear lifting bracket.
2.Systemic-

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4B

4

Cause and Effect Diagram
(Attach a copy of the diagram to the 8D report) OR (Use format included in "Attachments" sheet)

CLICK TO OPEN THE EXPANDED VIEW

US-QS4-002

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4C

5

US-QS4-002

5 - Why Analysis - keep asking "why" until you no longer have an answer
Process

Unhardened glue- Root Cause 1
Broken B material hose

Ask - Why did this happen?CLICK TO OPEN EXPANDED VIEW ON NEW TAB
Please refer to tab 3p5y_RMEP

Ask - Why did this happen?

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6

US-QS4-002

Identify Permanent Corrective Actions (PCA) - Determine solutions to address and correct the root cause(s) of the issue.

Choose the

solution deemed to be the best alternative.

Identify and Implement
#

Permanent Corrective Actions

1

Please refer to tab 3p5y_RMEP

Responsibility

Planned

Actual

(Date)

(Date)

Status

2
3
4

6

Verification of Permanent Corrective Actions (PCA) effectiveness - Verify the actions planned have been implemented
and have solved the problems. Ensure no undesired side-effects have been generated. If needed Copy Paste items from section 5 for verification

Validate
#

Permanent Corrective Actions

1

Please refer to tab 3p5y_RMEP

2
3
4

Responsibility

Planned

Actual

(Date)

(Date)

How
Verified

Status

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7

US-QS4-002

Prevention - (Design / Information System Review) - Determine what improvements in systems and processes would prevent problem from
reoccurring. Ensure that corrective action remains in place and successful.

7A Preventive measures
Action

Planned
(Date)

Responsibility

Actual
(Date)

Please refer to tab 3p5y_RMEP

7B

Update Documentation - Review and (if necessary) update the following documents / systems
Document

Need to update?

Responsibility

Planned

Actual

(Date)

(Date)

Status

Management System Manual
Manufacturing Work Instructions
Inspection Work Instructions
Flow Chart
Control Plans
Design FMEA
Process FMEA
Gauges
PPAP
Engineering Change Approval
Manufacturing Forms
Inspection Forms
Procedures
Error proofing / Poka Yokes
Process setup sheets
Internal Audit system

7C

Lessons Learned - Identify groups, individuals or processes (including those at sister locations), which should get informed about this 8D to determine
potential impact.
Group / Location

Responsibility

Monitoring the certification of the operators working on all the stations.

Quality Management Systems

7D Approval
Was the 8D Effective (team members, Management and customers as necessary)
Yes/No

8

Signature and title

Date

Congratulate Your Team - Celebrate successful conclusion of the problem solving effort. Formally
disengage the team.
8D Report will be archived for future reference and as document for lessons learned and how to make problem solving
better.

8D Closed
Date:

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US-QS4-002

This 8D report is a preliminary exclusively technical statement based on our information and the status of investigation at the date of its issuance under our express reservation of further investigations pertaining to
the root cause and containment actions. Irrespective of the use of terms in this form it does not include expressly nor implied any statement to contractual or statutory claims for compensation. It neither contains
nor constitutes directly or indirectly any kind of acknowledgement of fault or of claims of whatever nature.

Why did the process make the defect?

Prevent

Problem Definition:

Loose bottom lifting bracket at the
customer site leading to a safety
concern while lifting the engine along
leading to a safety issue.

Why did the Process
Produce?

The bottom bolt was found to be loose.

Why did the Process
Produce?

Process of installing the bolt and posting
the defect was not followed.

Why did the Process
Produce?

The operator backed out the bolts at
station 4680 since the bracket was not
aligned and torqued them using the air
tool.

Why did the Process
Produce?

The air tool allowed the bolts to be
backed out leading to loss of traceability
for torque values

Why did the process not detect or contain the defect?

Protect

The air tool allowed the bolts to be
Root Cause (Last Why) backed out leading to loss of traceability
for torque values

Problem Definition:

Loose bottom lifting bracket at the
customer site leading to the engine
falling off and causing safety issue while
lifting the engine.

There are no downstream checks in the
Why did the Process Not process to check if the bolts are torqued
Detect?
or seated correctly for the rear lifting
bracket.
There were no visual inspections/ torque
Why did the Process Not
inspections done to see if the bolts are
Detect?
torqued/seated properly.
Why did the Process Not
Detect?

Why did the process not
Why did the planning process not Predict the defect?

Predict

Why did the Process Not
Detect?
There were no visual inspections/ torque
Root Cause (Last Why) inspections done to see if the bolts are
torqued/seated properly.

Problem Definition:

The air tool allowed the bolts to be
backed out leading to loss of traceability
for torque values

Why did the Process Not The process did not consider the failure
Predict?
mode.
Why did the Process Not
Predict?
Why did the Process Not
Predict?

Why did the Process Not
Predict?

Root Cause (Last Why)

The process did not consider the failure
mode.

Loose bottom lifting bracket at the customer site
leading to a safety concern while lifting the engine
along leading to a safety issue.
Uncertified operator was running the station
without informing the Operations manager.
No process in place to communicate and have
approval for the uncertified operators running the