The defect or condition described below is chronic or repetitive in nature and your Corrective Action Response is required. Your response is necessary as evidence that action has been taken to prevent its reoccurance on future orders.

Please complete and return this I D E A S response before the due date shown above.

INSTRUCTIONS/CHECKLIST

• Identify the defect or problem.
  • Use a cross functional team from Engineering, Manufacturing and Quality Assurance to analyze the problem.
• Determine the Root Cause.
  • Ask Why did the problem occur, Why did it escape detection, What changed and what is different?
• Define the solution.
  • Brainstorm alternative corrective actions.
  • Rate each choice and select the corrctive action.
  • Document the change to be made.
  • Document the dates of implementation.
  • Mistake proof (poka-yoke) the process, if possible.
• Employ the solution.
  • Implement the solution or action plan.
  • Revise process tools, procedures and work instructions.
• Analyze the results, perform the necessary verification and validation.
  • Short term - can you re-start production? Perform capability study, pareto chart, SPC chart or alternative techniques.
  • Long term - Perform capability study and alternative techniques as above.
  • If not corrected, go back to determine the ROOT CAUSE or re-evaluate the employment actions.
• Summarize the findings and results.
  • Was the ROOT CAUSE determined and resolved?
  • Was the solution or action plan fully implemented and completed?
  • Were the results satisfactory?
  • Were all of the supporting documents (work instructions, procedures) updated?
  • Was the IDEAS form completed and returned to Elyria Manufacturing Corp?

List other Part Numbers, Processes or Areas where this solution should be implemented. Attach documentation indication results of review and/or implementation.