D3 Step – Containment Action

What Is containment action in the 8D Process? #

The D3 step_Containment Action is the first line of defense in the 8D problem-solving method.

Once the problem is clearly defined (D2), immediately take next step, to protect the customer from further nonconforming parts, or line stoppage due to defects until the permanent corrective action is found and validated.

“Containment doesn’t solve the problem, it gives you time to find the solution.”

In simple terms, D3 is about control, and communication.

Therefore, the Objective of D3 step is to:

• Stop defective material from reaching the customer.
• Isolate and control all suspect parts (at supplier, in-transit, and at customer).
• Verify stock status – in production, WIP, and finished goods.
• Communicate containment status to all stakeholders (internal & customer).
• Provide immediate assurance that the problem is under control.

How to update D3 Fields from 8D Template (Explained) #

Let’s review 8D template and each field exactly as it appears and understand what to record in containment action field.

1. Containment Action #

Document what immediate actions were taken to stop defect outflow and support the customer.

Example:

• Stopped dispatch of Lot #2310 to XYZ Motors ltd.
• Segregated all LH Seat Frame Brackets produced between 14 to 15 Oct 2025.
• Conducted 100% visual inspection on Welding Line 2 output.
• Sorted 250 pcs – 40 found with weak joints, 20 with minor spatters.
• All reworked parts marked with “OK-Green” sticker and tagged with rework ID.

These are temporary corrective actions, they do not remove the root cause but find out defect during ongoing production.

2. Parts Check Record #

In this section, record where checks were made, who performed them, and the results.

This table ensures traceability of ok parts and shows the example of controlled inspection.

3. OK / NOK Tagging and Traceability #

This section proves that you’ve physically identified which parts are safe.

Example:

• OK parts: Marked with a green sticker.
• NOK parts: Tagged with red ID labels and moved to rejection bin area.

Always ensure traceability records should match with batch and inspection data.

4. Remark Column #

Use this space to record any findings, line status, or feedback from the customer inspection team.

For example:

“Customer audit completed; no further defective parts detected post-sorting. All reworked parts accepted under deviation approval.”

Key Principles of Containment #

1. Immediate Response: Implement containment within 24 hours of issue identification.
2. Complete Isolation: Include all possible locations – supplier, warehouse, in-transit, and customer line.
3. Verification of Effectiveness: Ensure that no complaints arise after containment.
4. Temporary Nature: Containment remains active only until root cause (D4) and corrective action (D5) are verified.

Common types of Containment Actions in Automotive Manufacturing #

Practical Example – Seat Frame Welding Defect Case #

Let’s fill the D3 section of your 8D template based on the ongoing case.

How D3 Links to next steps

Once the containment done, the next logical steps are:

1. D4 – Root Cause Analysis = Containment data helps to narrow down the investigation to specific process, lot, or shift.
2. D5 – Corrective Action = Once corrective actions are implemented, containment can be removed after validation.

Containment Action Communication Example to Customer #

When containment is completed, a brief update should be sent:

“Dear [Customer Contact],

We have completed 100% inspection for Lot #2310 of LH Seat Frame Brackets.
Out of 2,000 pcs, 40 were found non-conforming and isolated. All OK parts were verified and re-labeled. No further issues observed during customer audit. Permanent root-cause analysis is in progress.

Regards,
Rahul Patil – Quality Team Leader, ABC Components Pvt Ltd.”

This communication feel customer more protected from defects and it is a sign of good quality engineer who deal with customer in good way.

Verification of Containment Effectiveness #

After the sorting/rework, verify through:

• Audit sampling at customer line.
• SPC or PPM monitoring for next shipments.
• Photographic or video evidence of inspection process.

If no new issues appear for 2 – 3 production lots, containment can be declared effective and closed during D6.

Summary of containment action #

• D3 = Immediate containment to protect the customer.
• Focus on isolation, inspection, and communication.
• Document all checks in 8D template’s “Containment Action” section.
• Verify that no further defective parts escape.
• Keep containment active until D6 confirms the corrective action is effective.

“Containment is not correction, it’s the safety net until you fix the real issue.”