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 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