Closed but Not Solved: Why Quality Problems Keep Returning—and How AI Can Help

Time:

Aug 27, 2026 11:00AM EST

Speakers:

Mike Popenas, Antony John

Abstract:

Why do quality problems return even after the corrective action is closed?

Industry data identifies problem-solving as the leading major IATF 16949 nonconformity, accounting for 10.31% of major findings—almost twice the next-highest category. This points to a serious gap: many organizations document problems but do not consistently identify the true root cause, validate corrective actions, or prevent recurrence.

In this 30-minute webinar, we will show how organizations can move beyond containment, firefighting, and administrative 8D closure to build a disciplined, evidence-based problem-solving process.

Participants will see how EQMS.AI Problem Solver can guide teams through issue definition, evidence collection, root-cause analysis, corrective-action planning, and effectiveness verification. AI Agents can help develop the 8D/CAPA, working with the Problem Solving Cross-functional team as an assistant, increasing efficiency and sharing knowledge and best practices.

Most importantly, problem-solving should not end when the 8D or CAPA is closed. The lessons learned must be taken back into the PFMEA, Control Plan, work instructions, inspection plans, and training. When actual failures are reflected in the FMEA, organizations can reassess risks, strengthen prevention and detection controls, and identify where the same failure could occur across other products, processes, plants, or suppliers.

This session will demonstrate how connected quality software and AI can transform problem-solving from a reactive reporting exercise into a powerful engine for prevention, risk reduction, and continuous improvement.

Key Takeaways

Attendees will learn how to:

• Recognize why corrective actions are often closed without the problem being truly solved.
• Separate containment and correction from verified root cause and systemic corrective action.
• How AI agents can assist teams in generating structured, evidence-based 8D and CAPA reports while improving root-cause analysis, corrective-action quality, and effectiveness verification.
• Feed lessons learned back into the PFMEA, Control Plan, Process Flow, work instructions, and training.
• Extend corrective actions across similar products, processes, suppliers, and manufacturing locations.

Benefits to the Audience

Participants will gain practical ideas to:

• Reduce repeat defects, customer complaints, and warranty issues.
• Improve the consistency and credibility of 8D and CAPA reports.
• Shorten investigation and corrective-action cycle times.
• Reduce dependence on a small number of experienced problem-solving experts.
• Improve audit readiness with clear evidence, approvals, traceability, and effectiveness verification.
• Keep FMEAs current using real manufacturing and field-performance data.
• Shift quality teams from recurring firefighting toward prevention and continuous improvement.