What is 8D Methodology?

Eight Disciplines of Problem Solving:

Establish the team Describe the problem Develop interim containment actions Define and verify root cause & escape points Choose and verify permanent corrective actions Implement and validate permanent corrective actions System prevention actions to prevent a recurrence Recognize team contributions

8D Problem Solving Example:

D1: Establish the Team:

D2: Describe the Problem:

D3: Develop Interim Containment Actions

D4: Define and Verify Root Cause & Escape Points:

D5: Choose and Verify Permanent Corrective Actions

Elimination Prevention Replacement Facilitation Detection Mitigation

D6: Implement and Validate Permanent Corrective Actions

D7: System Prevention Action to Prevent Recurrence

D8: Recognize Team Contributions

→ 8D Methodology is a systematic→ It was made popular by “Ford Motor Company” in the automotive industry.→ These are 8 disciplines or 8 steps that must be followed for identifying and eliminating a problem in a product, process, or service.➨ Purpose of D1:→ Establish a small group of people with relevant knowledge.➨ Key activities of the team in D1:→ Review priorities, scope, and problem→ Identify how big team is needed→ Identify team members and establish the team→ Nominate a team leader, project champion and facilitator→ Assign the roles and responsibilities➨ Purpose of D2:→ Describe the internal or external issue by identifying “what is wrong with what” and detailing the problem in quantifiable terms so it is easy to take further action.➨ Key activities in D2:→ Develop a problem statement and a flowchart of all operation steps and identify critical operation steps with respect to the_problem.→ Establish a high-level project plan, including milestones, project goals, and objectives.→ The description should define the boundaries.➨ We can use the below tools to describe the_problem.→ 5W2H method→ Why-Why Analysis➨ Purpose of D3:→ Define, verify and implement interim containment action to isolate the effects of the problem from any internal and/or external customer until permanent corrective (preventive) actions are implemented.➨ Key activities in D3:→ Define the interim containment action→ Verify the effectiveness of the interim containment action→ Select and implement interim containment action→ Validate the effectiveness of implemented interim containment action with the customer➨ The containment actions must be implemented at the below location:→ Customer's finished good (FG) storage→ At the customer's line→ Customer's RM storage→ Supplier's FG storage→ At the Supplier's line→ Supplier's RM storage→ Also, check at sub supplier's sequence of operation➨ We can use below tools for developing interim containment actions:→ Why-Why Analysis→ Check Sheet➨ Purpose of D4:→ In this stage, the root_cause is identified to take permanent action to eliminate the problem.➨ Key activities in D4:→ Development and verification of root_cause through data collection→ Review process flow for the location of the root_cause→ Determine the escape point→ The escape point is the closest point in the process where the root_cause could have been found but was not.➨ We can use below tools for define & verify root_cause & escape points→ Fishbone or Ishikawa diagram→ Why-Why Analysis→ Check Sheet→ Process Flow Chart➨ Purpose of D5:→ Select the best permanent corrective actions to eliminate the root cause in the process.➨ Key activities in D5:→ Develop and select the solution to remove the root cause & escape point→ Verify that effectiveness of the selected solutions➨ Six Mistake-Proofing Principles:➨ Various Mistake-Proofing Methods:⇢ Variation Control⇢ Workplace Organization⇢ Identification⇢ Process Checks⇢ Poka-Yoke Devices➨ Various Mistake-Proofing Devices:⇢ Guide Pins⇢ Error Detection & Alarms⇢ Limit Switches⇢ Sensors⇢ Vision Systems⇢ Counters & Timers⇢ Checklists➨ We can use below tools for Choose and Verify Permanent Corrective Actions:→ Fishbone or Ishikawa diagram→ Why-Why Analysis→ Check Sheet→ Scatter Diagram→ Process Flow Chart→ PFMEA (Process Failure Mode and Effect Analysis)→ Control Plan➨ Purpose of D6:→ Plan and implement selected Permanent Corrective Actions➨ Key activities in D6:→ Implement the best solution to remove the root cause & escape point→ Validate the effectiveness of the implemented action.→ Monitor the effectiveness of the implemented solutions and assure that they do not cause any undesirable effects.→ Communicate the plan to all relevant interested parties.➨ We can use below tools for implement and validate permanent corrective actions:or Fishbone→ Why-Why Analysis→ Check Sheet→ Scatter Diagram→ Process Flow Diagram➨ Purpose of D7:→ The purpose of the prevent recurrence is to share the knowledge, preventing_problems on similar products, processes, locations or families.➨ Key activities in D7:→ Review similar products and processes for problem_prevention (Horizontal Deployment)→ To update procedures and work instructions→ Assure PFD, PFMEA and Control Plan have been updated→ Check the needing standardization has been identified and implemented?➨ We can use below tools/documents to prevent recurrence:→ Cause & Effect Diagram or Fishbone→ Why-Why Analysis→ Check Sheet→ Scatter Diagram→ PFD (Process Flow Diagram)→ PFMEA (Process Failure Mode and Effect Analysis)→ Control Plan→ Work Instruction/SOP and Procedure➨ Purpose of D8:→ Identify the lesson(s) learned and celebrate the success of the team.➨ Key activities in D8:→ Perform a final review of the problem-solving project→ Prepare the report for future reference→ Document the lesson learned→ Before and after comparison of issue→ Recognize the team’s success and individual contributions➨ We can use below reports for the final stage in the 8D Methodology→ 8D Report→ Lesson Learned Report→ Before and After Comparison of issue