The Monday Board is a one-page checklist of eight actions, one for each step a customer complaint goes through. Each takes a few minutes, 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 complaint log
Pull your last three customer complaints.
For each one, check whether the part, lot, quantity, what the customer saw, and the due date are written in one place.
If any live only in an email, move them into your log today.
Chapter 1: The Complaint Arrives02 · The 8D report, steps D1 to D3
Open your oldest open corrective action.
Check that D3 covers all four places: customer, transit, finished goods and work in process.
If the clean break point isn't written down, write it today.
Chapter 2: Contain It03 · 5 Why and fishbone, step D4
Pull one closed corrective action.
Check whether it answers all three legs: occurrence, detection and system.
If it stops at "retrain operator," ask the next why with the team this week.
Chapter 3: Find the Cause04 · The process FMEA
Find the last step on your PFMEA.
Walk the floor from that step to the shipping dock.
List every step you pass that isn't on the PFMEA.
Chapter 4: Fix the Risk05 · The control plan
Pick five rows from one control plan.
Read each reaction plan out loud.
If any says only "notify supervisor," rewrite it as steps this week.
Chapter 5: Lock It In06 · The work instruction
Walk to one station and read the instruction posted there.
Check its revision against the current one in your system.
If they don't match, pull the old one today.
Chapter 6: Change the Work07 · The layered process audit
Pick your last three customer complaints.
Check whether each one left a question on your LPA.
Add one question this week for any that didn't.
Chapter 7: Check the Floor08 · The effectiveness check, step D8
List every corrective action closed in the last six months.
Check that each one has a written effectiveness check with evidence.
Reopen any that closed on the day the fix went in.
Chapter 8: Prove It Worked
ShopFloorOps · shopfloorops.com/field-book/monday-board/
Based on the made-up complaint RMA-031 in One Complaint: The Complaint-to-Closure Trail. Use your own forms; every check works with whatever records you already keep.