8D _ Problem Solving
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The 8D process is Ford Motor Company's problem solving methodology. It involves 8 disciplines: (1) recognizing the problem, (2) establishing a team, (3) describing the problem, (4) determining containment actions, (5) identifying potential causes, (6) selecting and verifying corrective actions, (7) implementing and validating corrective actions, and (8) preventing future recurrence. The goal is to eliminate nonconformities, protect customers, and ensure corrective actions address the root cause and prevent problems from reoccurring. The 8D approach provides a structured, fact-based process for problem analysis, verification of solutions, and documentation of lessons learned.
8D _ Problem Solving
- 1. 8D Invention Ford Motor Company started a problem solving process known as 8D which takes 8 Disciplines and uses them to tackle engineering problems For Internal Use Only Presentation by Senthilkumar RM
- 2. Why to Go ? • To Eliminate the cause of Detected Non conformity • To protect the customer from receiving or using nonconforming product • Corrective action is taken to prevent recurrence For Internal Use Only Presentation by Senthilkumar RM
- 3. Why 8D ? • 8D is a structured approach to solving problems • Fact Based Data Collection & Analysis • Tests progress and results Verify & Validate • Documented History – An information database Anticipate future problems Prevent recurrence For Internal Use Only Presentation by Senthilkumar RM
- 4. 8D Flow D4: D5: Choose & D0: Recognize the Identify Potential Verify Corrective Problem Causes Actions D6: Implement & D1: Establish the Select Likely Validate Team Causes Corrective Actions D2: Describe the D7: Prevent No Root Cause ? Problem Recurrence Yes D3: Determine and Implement Identify Possible D8: Congratulate Containment Corrective Actions the Team Actions For Internal Use Only Presentation by Senthilkumar RM
- 5. D0 : Recognize the problem • Determining the structure of a problem assists in the selection of the correct tools to use. • It may give clues to the nature of the root causes Gradual change , deteriorating performance over time : Established Performance Time Sudden change , catastrophic change from standard : Established Performance Time For Internal Use Only Presentation by Senthilkumar RM
- 6. D0 : Continued .. Start-up, gap between expected and actual performance : Expected Performance Time Actual Performance Recurring change , comes and goes with unknown causes : Established Performance Time For Internal Use Only Presentation by Senthilkumar RM
- 7. D1 : Establish Team Establish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group selects a team leader • Cross Functional or Multi-Disciplinary • Process Owner • Technical Expert • Others involved in the containment, analysis, correction and prevention of the problem For Internal Use Only Presentation by Senthilkumar RM
- 8. D2 : Problem Description Problem statement = Object + concern + quantification • Describe the problem in measurable terms. • Specify the internal or external customer Remember: A well defined problem is half solved! For Internal Use Only Presentation by Senthilkumar RM
- 9. D3 : Containment Action •Define and implement those intermediate actions that Will protect the customer from the problem until permanent corrective action is implemented. •Verify with data the effectiveness of these actions. For Internal Use Only Presentation by Senthilkumar RM
- 10. D4 : Identify Root Cause • Identify potential causes which could explain why the problem occurred. • Test each potential cause against the problem description and data. • Identify alternative corrective actions to eliminate root cause. • Tools Used - 5Why ; Fishbone ; Scatter For Internal Use Only Presentation by Senthilkumar RM
- 11. D5 : Choose and verify Corrective action • After root causes and possible corrective actions have been identified, select the corrective actions that will permanently correct the problem. • Decision analysis may be needed if the choice is not obvious. • Verify that the selected corrective actions will resolve the problem •Tools used : Poke – Yoke For Internal Use Only Presentation by Senthilkumar RM
- 12. D6 : Implement and Validate CA • Implementation can proceed when best corrective action has been selected & verified. • An effective implementation plan reduces problems. • Validation is obtained by tracking performance over time after implementation to ensure the corrections are permanent. For Internal Use Only Presentation by Senthilkumar RM
- 13. D7 : Prevent System Recurrence • Implement the corrective actions in other potentially affected areas • Ensure the systems that allowed the problem to occur and escape have been corrected • The problem is now Solved & requiring a larger scale continual improvement project of some type For Internal Use Only Presentation by Senthilkumar RM
- 14. D8 : Congratulate the Team • Recognize the collective efforts of your team. • Publicize your achievement. • Share your knowledge and learning. For Internal Use Only Presentation by Senthilkumar RM
- 15. Quick Ponder !! • What is D Stands for in 8D? • Who invented in 8D? • Title 8D ? Thank you all !! For Internal Use Only Presentation by Senthilkumar RM