8D Methodology | Problem Solving Method | Example

What’s 8D Methodology?

  • 8D Methodologyis a methodical problem- solving tools or you can say it’s a strategy.
  • It wasmade popular by “ Ford Motor Company” in the automotive industry. And now it has been widely used by many organisation across the globe
  • These are 8 disciplinesor 8 steps thatJust be followed for identifying and barring a problem in a product, process, or service.

Eight steps  of Problem Solving

  1. Establishthe team
  2. Describethe problem
  3. Developinterim containment actions
  4. Defineand validate root cause & escape points
  5. Chooseand validate endless corrective actions
  6. Implementand validate endless corrective actions
  7. Systemprevention actions to help a recurrence
  8. Feteteam contributions

8D Problem Solving Illustration

Step 1  Establish the Team

  • Purpose
  • Establish a small group of people with applicable knowledge.
  • Key activities of the team in step 1
  • Review priorities, scope, and problem
  • Identify how big team is demanded
  • Identify team members and establish the team
  • Nominate a team leader, project champion and facilitator Assign the places and liabilities

Step 2 Describe the Problem

Purpose of STEP 2

  • Describe the internal or external issue by relating “ what is wrong with what” and detailing the problem in quantifiable terms so it’s easy to take more action.

Key exercise in STEP 2

  • 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 objects.
  • The description should define the boundaries.

We can use the below tools to describe the problem.

  • 5W2H strategy
  • Why-Why Analysis
  • Check Sheet

STEP 3 Develop Interim Containment Actions 

Purpose of STEP 3

  • Define, validate and apply interim containment action to insulate the effects of the problem from any internal and/ or external client until permanent corrective (preventative) conduct is enforced.

Key activities in STEP 3

  • Define the interim containment action
  • Verify the effectiveness of the interim containment action
  • Select and apply interim constraint action
  • Validate the effectiveness of implemented interim containment action with the client

The containment actions must be enforced at the below position 

  • Client’s finished good (FG) warehouse
  • At the client’s line
  • Client’s RM warehouse
  • Supplier’s FG warehouse
  • At the Supplier’s line
  • Supplier’s RM warehouse
  • Also, check at sub supplier’s sequence of operation

We can use the below tools for developing interim containment actions 

  • Why-Why Analysis
  • Check Sheet
  • Process Flow Diagram

STEP 4 Define and validate Root Cause & Escape Points 

Purpose of STEP 4

  • In this stage, the root cause is linked to take permanent action to exclude the problem.

Key exercise in STEP 4

  • Development and verification of root cause through data collection
  • Review process flow for the place 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 plant but was not.

We can use the below tools for define & validate the root cause & escape points 

  • Fishbone or Ishikawa illustration
  • Why-Why Analysis
  • Check Sheet
  • scattering Diagram
  • Process Flow Chart

STEP 5 Choose and Verify Endless Corrective Actions 

Purpose of STEP 5

  • Select the best permanent corrective conduct to eliminate the root cause in the process.

Key conditioning in STEP 5

  • Develop and select the result to remove the root cause & escape point
  • validate that effectiveness of the selected results

Six Mistake-Proofing Principles

  1. Elimination
  2. Prevention
  3. Replacement
  4. Facilitation
  5. Detection
  6. Mitigation

SeveralMistake-Proofing techniques 

  • Variation Control
  • Workplace Organization
  • Identification ⇢Process Checks
  • Poka-Yoke Devices

VariousMistake-Proofing Devices 

  • Guide Pins
  • Error Detection & Alarms
  • Limit Switches
  • Sensors
  • Vision Systems
  • Counters& Timers
  • Checklists

We can usebelow tools for Choose and validate Permanent Corrective Actions

  • Fishbone or Ishikawa illustration
  • Why-Why Analysis
  • CheckSheet
  • scatteringDiagram
  • ProcessFlow Chart
  • PFMEA ( ProcessFailure Mode and Effect Analysis)
  • ControlPlan

STEP 6 Implement and Validate Permanent Corrective Actions 

Purposeof STEP 6

  • Planand implement selected Permanent Corrective Actions

Key activitiesin STEP 6

  • Implementthe best result to remove the root cause & escape point
  • Validatethe effectiveness of the implemented action.
  • Monitorthe effectiveness of the enforced results and assure that they don’t cause any undesirable effects.
  • Communicatethe plan to all applicable interested parties.

We can usebelow tools for apply and validate endless corrective actions 

  • Causeand Effect Diagram or Fishbone
  • Why-Why Analysis
  • CheckSheet
  • scatteringDiagram
    • ProcessFlow Diagram

STEP 7 System Prevention Action to Prevent Recurrence

Purposeof STEP 7

  • The purposeof the prevent recurrence is to partake the knowledge, preventing problems on similar products, processes, places or families.

Key exercisein STEP 7

  • Reviewsimilar products and processes for problem prevention (Horizontal Deployment)
  • To updateprocedures and work instructions
  • AssurePFD, PFMEA and Control Plan have been updated
  • Checkthe demanding standardization has been identified and implemented?

We can usebelow toolsdocuments to prevent rush

  • Cause& Effect Diagram or Fishbone
  • Why-Why Analysis
  • CheckSheet
  • scatteringDiagram
  • PFD ( ProcessFlow Diagram)
  • PFMEA ( ProcessFailure Mode and Effect Analysis)
  • ControlPlan
  • WorkInstruction/ Bribe and Procedure

STEP 8 Recognize Team Contributions 

Purposeof STEP 8

  • Identifythe lesson (s) learned and celebrating the success of the team.

Key exercisein STEP 8

  • Performa final review of the problem- solving project
  • Preparethe report for future reference
  • Documentthe lesson learned
  • Before and after comparison of issue
  • Recognizethe team’s success and individual contributions

We can usebelow reports for the final stage in the 8D Methodology 

  • 8D Report
  • LessonLearned Report
  • Before and After Comparison of issue

Leave a Reply

Your email address will not be published. Required fields are marked *