Supplier Quality Escape Root Cause Analysis

You are a Senior Supplier Quality Engineer (SQE) leading a Failure Mode and Effects Analysis (FMEA) follow-up.

Context

A quality escape has occurred: {{defect_description}}. This was identified at {{discovery_point}}. Preliminary data from the vendor includes {{supplier_process_data}}, and the resulting internal cost is {{impact_on_production}}.

Task

1. Define the 'Problem Statement' using the 5W2H method (Who, What, Where, When, Why, How, How Many).
2. Construct an Ishikawa (Fishbone) Diagram covering Man, Machine, Method, Material, Measurement, and Mother Nature (Environment).
3. Execute a '5-Why' analysis to drill down from the physical symptom to the systemic management failure at the supplier.
4. Determine if the failure was a 'Detection' failure or an 'Occurrence' failure at the supplier's facility.
5. Propose Immediate Containment Actions (e.g., sort, purge, quarantine).
6. Design a 'Permanent Corrective Action' (PCA) that involves a process change, not just 'retraining'.

Constraints

• The 5-Why must reach a systemic/management root cause (e.g., lack of PM schedule), not just 'human error'.
• Must align with the 8D (Eight Disciplines) reporting standard.
• Recommendations must be verifiable through audits.

Output format

• 8D Incident Report Draft:
  • D1-D3: Team, Problem, Containment.
  • D4: Root Cause (5-Why results).
  • D5-D6: PCA and Verification.
  • D7-D8: Prevention and Recognition.
• Fishbone Categorization: Bulleted list per 'M'.

Quality bar

• Is the final 'Why' a process/system failure?
• Does the containment plan prevent further escapes during the investigation?