The Monday Board is a one-page checklist of eight actions, one for each step a repeat defect goes through. Each uses records you already have and finds a real gap if one exists. Print it, pin it up and tick them off.
Download the printable board (PDF)
01 · The last fix
Pull your last corrective action for a defect that came back and mark each cause proven, stated or missing.
Chapter 1: Review the Last Fix02 · The problem statement
Write both occurrences side by side: what is the same, what changed.
Chapter 2: Restate the Problem03 · The containment
Check that all four containment places have a number, even if it is 0, and name the first clean lot.
Chapter 3: Contain It04 · The 5 Why
Ask why the defect was not caught, and check what your current gage can and cannot read.
Chapter 4: 5-Why05 · The fishbone
Count the empty branches on your last fishbone and mark each confirmed, ruled out or unknown.
Chapter 5: Fishbone06 · The corrective action
Mark each action on your last corrective action remove, error proof, detect or train. Replace any that is only training.
Chapter 6: Corrective Action07 · The lock in
Check that the PFMEA, control plan and work instruction say the same thing about one closed repeat.
Chapter 7: Lock It In08 · The effectiveness check
Compare the window on your last effectiveness check with how often the failure can happen.
Chapter 8: Effectiveness Check
ShopFloorOps · shopfloorops.com/field-book-5/monday-board/
Based on the made-up sensor bracket BK-6139 in One Comeback. The Repeat Defect Trail. The part, die and numbers are made up. Use your own forms; every check works with whatever records you already keep.