2. P roblem S olving I nnovator Solving Tomorrows Problems Today IS - IS NOT / COMPARITIVE ANALYSIS motivates deliberate thinking about the Boundaries of What Is or Is Not. WHAT Object / Deviation WHERE Seen on Product / Process WHERE Seen on Product / Process WHEN First seen / Last Reported WHEN First seen / Last Reported HOW BIG How many objects / Defects HOW BIG How many objects / Defects

3. COVER PAGE

4. D2 – Fill in the data for the WHAT section accordingly WHAT section Help What object has the Defect? Auto Input from Problem Workbook Help What similar object(s) could have the Defect Help CONSIDER Part Numbers Shop Floor Descriptions Customer Descriptions Help What is the Defect? Auto Input from Problem Workbook Help What other Defects could have been observed? Help What has changed In / and / around this difference? Help Date change was reversed. If still same ? Enter current Help How could these Differences or Changes have Created or Caused the Problem – as it is defined? Other Similar Valves Major Leak Data to confirm Problem has not previously occurred on similar Parts Help What 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 Help CONSIDER How could the changes Have CAUSED the differences Used only by TooGood Motor Corporation Current

5. D2 – Fill in the data for the WHERE section accordingly WHERE section Help Where specifically on the object does the Defect occur? Help Where in the Process Flow is the Defect seen Help Where specifically on the object does the Defect occur? Help Where could the Defect have been observed? Help CONSIDER Environmental factors Contamination Possible Abuse Help What could CAUSE the Difference between the IS compared to the IS NOT? Help CONSIDER How could the changes have CAUSED the differences Help What has changed In / and / around this difference? Help How 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

6. D2 – Fill in the data for the WHEN section accordingly WHEN section Help What has changed In / and / around this 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 Help When in time was the Defect first observed? Help When was it Seen But NOT Reported Help When in time could the Defect have been observed? Help Where should the Defect have been seen, but wasnt. Help CONSIDER Mode of Operation Modifications/ Changes Reliability Data Help What could CAUSE the Difference between the IS compared to the IS NOT? Help CONSIDER How could the changes have CAUSED the differences Help How could these Differences or Changes have Created or Caused the Problem – as it is defined? Help When since that time has it been seen? Help Consider changes in the Process Cycle.

7. HOW BIG section D2 – Fill in the data for the HOW BIG section accordingly Help What has changed In / and / around this difference? Help How many units, items, objects, have the defect? Use % or how many out of? Help Is the Problem getting Bigger/ Stable / Smaller? Help How often could the Defect occur Help Could the Problem be worse or better without intervention? Help CONSIDER Warranty Returns Quality Records CP / Cpk Help What could CAUSE the Difference between the IS compared to the IS NOT? Help How could these Differences or Changes have Created or Caused the Problem – as it is defined? Help How many Defects per Object, Part or Unit? Help CONSIDER How 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 Help How many objects could have had the Defect?

8. P roblem S olving I nnovator Solving Tomorrows Problems Today This completes the D2 Comparative Analysis Now start the Flow Chart