Free 8D, 5 Whys, Fishbone, PFMEA and Kaizen Templates

We've published five problem-solving templates as free PDFs. Each one has instructions on the page, so the team can work through it without a separate guide. You can type into them on screen or print them for the shop floor. They're free to use and share.

The templates

8D Problem Solving Report. Steps D0 to D8, from containment through root cause to closure, in the format most customers expect. Download the 8D template (3 pages).
5 Whys. Ask why across Man, Machine, Method and Material, then check the chain and record the actions. Download the 5 Whys template (2 pages).
Fishbone (Ishikawa) diagram. List possible causes in six groups, then pick the likeliest and test them. Download the fishbone template (2 pages).
Process FMEA. Severity, occurrence and detection guides, with 75 rows of worksheet for RPN or Action Priority. Download the PFMEA template (6 pages).
Kaizen improvement sheet. Measure the current state, spot the waste, try a fix and make it the new standard. Download the kaizen template (2 pages).

Which one to use

Use the 8D when a customer has raised a complaint or the problem needs a formal record. Use the 5 Whys or the fishbone to get to the cause, either on their own or as part of D4 of an 8D. Use the PFMEA before production starts, and keep it up to date afterwards. Use the kaizen sheet for small improvements the team can make in days.

All five are on the Consultancy page too. If you'd like help running any of them with your team, email enquiries@grindstone.ltd.