Repeat Defect Trail Bundle Excel | 12 Quality Tools: CAR Tracker, 8D, A3, 5 Why, Fishbone, PFMEA, Control Plan, LPA | iatf 16949

A defect that comes back is not a new problem. It is the old one, still open. Fixing the part again does not fix it. This bundle gives you a working Excel tool for every step of the trail, from the repeat on the log to proof that the fix held, built to hand off from one step to the next.

It is the companion to the free field book “One Comeback. The Repeat Defect Trail.” The book walks the 8 steps. This bundle gives you the 12 tools to run them.

The 12 tools, step by step

Step 1: Log the repeat

QA-F-375 CAR Tracker: keep every corrective action and noncompliance in one multi-year register, with live open, in progress, closed and on hold status.

Step 2: Contain it

QA-F-215 NCM Red Tag Log: tag the suspect material and log where it is.
QA-F-200 Quality Alert Form: tell the floor what the problem is and what to do about it, with operator acknowledgment.

Step 3: Frame the problem

QA-F-355 8D Corrective Action Form: D1 through D8 on one form, from containment to preventing it again.
QA-F-360 A3 Problem Solving Template: put the whole problem on one page, from background and current state to countermeasures and results.

Step 4: Find the real cause

QA-F-310 3-Legged 5 Why Analysis: ask why it happened, why it was not caught and why the system allowed it.
QA-F-365 Fishbone Diagram: lay out the possible causes by man, machine, method, material, measurement and environment.

Step 5: Fix the system

QA-F-340 Process FMEA Template: re-rate the risk after the fix, with severity, occurrence and detection scored.
QA-F-350 Control Plan Template: add the detection that would have caught it, with method, sample, frequency and reaction plan.

Step 6: Change the work

QA-F-390 Work Instruction & Change Release: write the instruction for the station, release the change on the record and sign off the training.

Step 7: Prove it held

QA-F-393 Effectiveness Verification Tracker: checks at 30, 60 and 90 days, recurrences counted, with a closure gate that says close, hold or reopen.

Step 8: Keep watching

QA-F-205 Layered Process Audit: keep checking the process at every layer so the defect does not come back.

One trail, start to finish

Log and contain: count the repeat, tag the material, alert the floor
Frame and find the cause: 8D or A3, then the 5 why and the fishbone
Fix the system: re-rate the risk, update the control plan, release the new instruction
Prove it and keep watching: timed checks, then a layered audit

How this differs from our other bundles
The Root Cause Corrective Action bundles stay available as shorter, entry-level sets for the investigation itself. The Complaint-to-Closure Trail Bundle follows one customer complaint from the first report to a proven fix. The Repeat Defect Trail Bundle is for the defect that keeps coming back, from the repeat on the log to proof the fix held.

Details

12 Excel workbooks in one instant download
Works with Excel 2016, 2019, 2021 and Microsoft 365
Parts, customers and examples are generic, so replace them with your own
Open each workbook’s instructions tab for setup

Built by a quality practitioner for quality practitioners: quality engineers, quality managers, manufacturing engineers, supervisors, and IATF 16949 / ISO 9001 sites. Standards referenced for informational alignment only. Not a certification.