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
- Establishthe team
- Describethe problem
- Developinterim containment actions
- Defineand validate root cause & escape points
- Chooseand validate endless corrective actions
- Implementand validate endless corrective actions
- Systemprevention actions to help a recurrence
- 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
- Elimination
- Prevention
- Replacement
- Facilitation
- Detection
- 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 tools/ documents 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
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