8d structured problem solving pdf

Eight Disciplines of Problem Solving (8D)

– Eight Disciplines of Problem Solving –

⇓   Introduction to 8D

⇓   What is 8D

⇓   Why Apply 8D

⇓   When to Apply 8D

⇓   How to Apply 8D

Introduction to Eight Disciplines of Problem Solving (8D)

The Eight Disciplines of Problem Solving (8D) is a problem solving methodology designed to find the root cause of a problem, devise a short-term fix and implement a long-term solution to prevent recurring problems. When it’s clear that your product is defective or isn’t satisfying your customers, an 8D is an excellent first step to improving Quality and Reliability.

Ford Motor Company developed this problem solving methodology, then known as Team Oriented Problem Solving (TOPS), in the 1980s. The early usage of 8D proved so effective that it was adopted by Ford as the primary method of documenting problem solving efforts, and the company continues to use 8D today.

8D has become very popular among manufacturers because it is effective and reasonably easy to teach. Below you’ll find the benefits of an 8D, when it is appropriate to perform and how it is performed.

What is Eight Disciplines of Problem Solving (8D)

The 8D problem solving process is a detailed, team oriented approach to solving critical problems in the production process. The goals of this method are to find the root cause of a problem, develop containment actions to protect customers and take corrective action to prevent similar problems in the future.

The strength of the 8D process lies in its structure, discipline and methodology. 8D uses a composite methodology, utilizing best practices from various existing approaches. It is a problem solving method that drives systemic change, improving an entire process in order to avoid not only the problem at hand but also other issues that may stem from a systemic failure.

8D has grown to be one of the most popular problem solving methodologies used for Manufacturing, Assembly and Services around the globe. Read on to learn about the reasons why the Eight Disciplines of Problem Solving may be a good fit for your company.

Why Apply Eight Disciplines of Problem Solving (8D)

The 8D methodology is so popular in part because it offers your engineering team a consistent, easy-to-learn and thorough approach to solving whatever problems might arise at various stages in your production process. When properly applied, you can expect the following benefits:

• Improved team oriented problem solving skills rather than reliance on the individual
• Increased familiarity with a structure for problem solving
• Creation and expansion of a database of past failures and lessons learned to prevent problems in the future
• Better understanding of how to use basic statistical tools required for problem solving
• Improved effectiveness and efficiency at problem solving
• A practical understanding of Root Cause Analysis (RCA)
• Problem solving effort may be adopted into the processes and methods of the organization
• Improved skills for implementing corrective action
• Better ability to identify necessary systemic changes and subsequent inputs for change
• More candid and open communication in problem solving discussion, increasing effectiveness
• An improvement in management’s understanding of problems and problem resolution

8D was created to represent the best practices in problem solving. When performed correctly, this methodology not only improves the Quality and Reliability of your products but also prepares your engineering team for future problems.

When to Apply Eight Disciplines of Problem Solving (8D)

The 8D problem solving process is typically required when:

• Safety or Regulatory issues has been discovered
• Customer complaints are received
• Warranty Concerns have indicated greater-than-expected failure rates
• Internal rejects, waste, scrap, poor performance or test failures are present at unacceptable levels

How to Apply Eight Disciplines of Problem Solving (8D)

The 8D process alternates inductive and deductive problem solving tools to relentlessly move forward toward a solution. The Quality-One approach uses a core team of three individuals for inductive activities with data driven tools and then a larger Subject Matter Expert (SME) group for the deductive activities through brainstorming, data-gathering and experimentation.

D0: Prepare and Plan for the 8D

Proper planning will always translate to a better start. Thus, before 8D analysis begins, it is always a good idea to ask an expert first for their impressions. After receiving feedback, the following criterion should be applied prior to forming a team:

Collect information on the symptoms

Use a Symptoms Checklist to ask the correct questions

Identify the need for an Emergency Response Action (ERA), which protects the customer from further exposure to the undesired symptoms

D1: Form a Team

A Cross Functional Team (CFT) is made up of members from many disciplines. Quality-One takes this principle one step further by having two levels of CFT:

• The Core Team Structure should involve three people on the respective subjects: product, process and data
• Additional Subject Matter Experts are brought in at various times to assist with brainstorming, data collection and analysis

Teams require proper preparation. Setting the ground rules is paramount. Implementation of disciplines like checklists, forms and techniques will ensure steady progress.  8D must always have two key members: a Leader and a Champion / Sponsor:

• The Leader is the person who knows the 8D process and can lead the team through it (although not always the most knowledgeable about the problem being studied)
• The Champion or Sponsor is the one person who can affect change by agreeing with the findings and can provide final approval on such changes

D2: Describe the Problem

The 8D method’s initial focus is to properly describe the problem utilizing the known data and placing it into specific categories for future comparisons. The “Is” data supports the facts whereas the “Is Not” data does not. As the “Is Not” data is collected, many possible reasons for failure are able to be eliminated. This approach utilizes the following tools:

• Problem Statement
• Affinity Diagram (Deductive tool)
• Fishbone/Ishikawa Diagram (Deductive tool)
• Problem Description

D3: Interim Containment Action

In the interim, before the permanent corrective action has been determined, an action to protect the customer can be taken. The Interim Containment Action (ICA) is temporary and is typically removed after the Permanent Correct Action (PCA) is taken.

• Verification of effectiveness of the ICA is always recommended to prevent any additional customer dissatisfaction calls

D4: Root Cause Analysis (RCA) and Escape Point

The root cause must be identified to take permanent action to eliminate it. The root cause definition requires that it can be turned on or off, at will. Activities in D4 include:

• Comparative Analysis listing differences and changes between “Is” and “Is Not”
• Development of Root Cause Theories based on remaining items
• Verification of the Root Cause through data collection
• Review Process Flow Diagram for location of the root cause
• Determine Escape Point, which is the closest point in the process where the root cause could have been found but was not

D5: Permanent Corrective Action (PCA)

The PCA is directed toward the root cause and removes / changes the conditions of the product or process that was responsible for the problem. Activities in D5 include:

• Establish the Acceptance Criteria which include Mandatory Requirements and Wants
• Perform a Risk Assessment /  Failure Mode and Effects Analysis (FMEA) on the PCA choices
• Based on risk assessment, make a balanced choice for PCA
• Select control-point improvement for the Escape Point
• Verification of Effectiveness for both the PCA and the Escape Point are required

D6: Implement and Validate the Permanent Corrective Action

To successfully implement a permanent change, proper planning is essential. A project plan should encompass: communication, steps to complete, measurement of success and lessons learned. Activities in D6 include:

• Develop Project Plan for Implementation
• Communicate the plan to all stakeholders
• Validation of improvements using measurement

D7: Prevent Recurrence

D7 affords the opportunity to preserve and share the knowledge, preventing problems on similar products, processes, locations or families. Updating documents and procedures / work instructions are expected at this step to improve future use. Activities in D7 include:

• Review Similar Products and Processes for problem prevention
• Develop / Update Procedures and Work Instructions for Systems Prevention
• Capture Standard Work / Practice and reuse
• Assure FMEA updates have been completed
• Assure Control Plans have been updated

D8: Closure and Team Celebration

Teams require feedback to allow for satisfactory closure. Recognizing both team and individual efforts and allowing the team to see the previous and new state solidifies the value of the 8D process. Activities in D8 include:

• Archive the 8D Documents for future reference
• Document Lessons Learned on how to make problem solving better
• Before and After Comparison of issue
• Celebrate Successful Completion

8D and Root Cause Analysis (RCA)

The 8D process has Root Cause Analysis (RCA) imbedded within it. All problem solving techniques include RCA within their structure. The steps and techniques within 8D which correspond to Root Cause Analysis are as follows:

• Problem Symptom is quantified and converted to “Object and Defect”
• Problem Symptom is converted to Problem Statement using Repeated Whys
• Possible and Potential Causes are collected using deductive tools (i.e. Fishbone or Affinity Diagram)
• Problem Statement is converted into Problem Description using Is / Is Not
• Problem Description reduces the number of items on the deductive tool (from step 3)
• Comparative Analysis between the Is and Is Not items (note changes and time)
• Root Cause theories are developed from remaining possible causes on deductive tool and coupled with changes from Is / Is Not
• Compare theories with current data and develop experiments for Root Cause Verification
• Test and confirm the Root Causes

Example: Multiple Why Technique

The Multiple / Repeated Why (Similar to 5 Why) is an inductive tool, which means facts are required to proceed to a more detailed level. The steps required to determine problem statement are:

• Problem Symptom is defined as an Object and Defect i.e. “Passenger Injury”
• Why? In every case “SUV’s Roll Over”
• Why? In every case, it was preceded by a “Blown Tire”
• Why? Many explanations may be applied, therefore the team cannot continue with another repeated why past “Blown Tire”
• Therefore, the Problem Statement is “Blown Tire”
• Why? Low (Air) Pressure, Tire Defect (Degradation of an Interface) and High (Ambient) Temperature
• Counter measures assigned to low pressure and tire defect

This example uses only 4 of the 5 Whys to determine the root causes without going further into the systemic reasons that supported the failure. The Repeated Why is one way to depict this failure chain. Fault Tree Analysis (FTA) could also be used.

The Basics of Structured Problem-Solving Methodologies: DMAIC & 8D

Topics: Minitab Engage

When it comes to solving a problem, organizations want to get to the root cause of the problem, as quickly as possible. They also want to ensure that they find the most effective solution to that problem, make sure the solution is implemented fully, and is sustained into the future so that the problem no longer occurs. The best way to do this is by implementing structured problem-solving. In this blog post, we’ll briefly cover structured problem-solving and the best improvement methodologies to achieve operational excellence. Before we dive into ways Minitab can help, let’s first cover the basics of problem-solving.

WHAT IS STRUCTURED PROBLEM-SOLVING?

Structured problem-solving is a disciplined approach that breaks down the problem-solving process into discrete steps with clear objectives. This method enables you to tackle complex problems, while ensuring you’re resolving the right ones. It also ensures that you fully understand those problems, you've considered the reasonable solutions, and are effectively implementing and sustaining them.

WHAT IS A STRUCTURED PROBLEM-SOLVING METHODOLOGY?

A structured problem-solving methodology is a technique that consists of a series of phases that a project must pass through before it gets completed. The goal of a methodology is to highlight the intention behind solving a particular problem and offers a strategic way to resolve it. WHAT ARE THE BEST PROBLEM-SOLVING METHODOLOGIES?

That depends on the problem you’re trying to solve for your improvement initiative. The structure and discipline of completing all the steps in each methodology is more important than the specific methodology chosen. To help you easily visualize these methodologies, we’ve created the Periodic Table of Problem-Solving Methodologies. Now let’s cover two important methodologies for successful process improvement and problem prevention: DMAIC and 8D .

8D is known as the Eight Disciplines of problem-solving. It consists of eight steps to solve difficult, recurring, or critical problems. The methodology consists of problem-solving tools to help you identify, correct, and eliminate the source of problems within your organization. If the problem you’re trying to solve is complex and needs to be resolved quickly, 8D might be the right methodology to implement for your organization. Each methodology could be supported with a project template, where its roadmap corresponds to the set of phases in that methodology. It is a best practice to complete each step of a given methodology, before moving on to the next one.

MINITAB ENGAGE, YOUR SOLUTION TO EFFECTIVE PROBLEM-SOLVING

Minitab Engage TM was built to help organizations drive innovation and improvement initiatives. What makes our solution unique is that it combines structured problem-solving methodologies with tools and dashboards to help you plan, execute, and measure your innovation initiatives! There are many problem-solving methodologies and tools to help you get started. We have the ultimate end-to-end improvement solution to help you reach innovation success.

Ready to explore structured problem-solving?

Download our free eBook to discover the top methodologies and tools to help you accelerate your innovation programs.

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8D Structured Problem Solving

• Each step is thoroughly defined with examples and common pitfalls
• Includes a full set of sample forms so you can start today
• Learn how to integrate 8D Problem Solving methods into your environment
• Thought the material in this book was presented in a logical and easily understandable format. A good place to start if a company wants to start an 8D program.
• Used as a text book for supervisor training in the 8D process. We intend to use the 8 disciplines as a formal way of structuring our improvment projects. The book worked well as a tool for training. Because each supervisor now has a copy as a reference, I think the system will grow effectively.
• Worked my way through a problem using their forms. The whole process didn't take very long. I typed up a full report for my boss and a distilled version for the client using the book's examples as a guide. My boss loved the report and even the very restrained client said, "Very nice." which is like anyone else shouting, "EXCELLENT." The examples, blank forms and sample reports were exactly what I needed. Next time I have to do an 8D report, I am pulling the book off the shelf.

• Published: 2011
• Paperback: 148 pages
• Language: English
• ISBN: 978-0979055317

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8D problem solving: how to diagnose & eliminate quality problems

Diagnosing and eliminating quality problems is at the heart of all Quality Management. There are several methodologies as to how to do this. One of the most widely implemented is 8D problem solving. This tried-and-true methodology gives teams a comprehensive and consistent way to address production problems, no matter where they are triggered along the production chain.

Several articles elaborate on why it’s important to diagnose and eliminate quality problems using the 8Ds. But how does this work if you’re using  quality management software ? Let’s find out

A quick intro to 8D problem solving

The Eight Disciplines of problem solving (8D) provides manufacturers with a team-oriented approach to addressing problems in the production cycle. It’s widely used throughout manufacturing and combines best practices from a variety of approaches to create a “best of all worlds” scenario. High-level goals folded into the 8D process include:

• Identifying the root cause of a problem
• Developing containment actions that protect customers

Organizations that employ 8D should experience systemic changes to their production process. They will also be able to improve and streamline the whole process. This helps them to eliminate the problem at hand but also reduce the occurrences of other problems down the line

So, what do the 8Ds stand for?

To achieve the high-level goals described above, a team should pursue these eight steps:

• Define the stakeholders addressing the problem.
• Develop a Problem Statement that correctly summarizes and defines the problem.
• Define and execute an interim containment action.
• Document the root cause of the non-conformance or non-detection, along with the                percentage at which it contributed to the problem.
• Define, select, and verify Corrective Action(s) needed to address the problem.
• Implement and validate the Corrective Action(s).
• Document all actions taken to prevent recurrence.
• Document and acknowledge the team contributions that led to the success of this                  process.

When to apply 8D problem solving

Typically, 8D is most applicable in the following scenarios:

• when safety or regulatory issues have come up in the production cycle
• if your company receives multiple and consistent customer complaints
• when warranty responses suggest product failure rates that are higher than expected
• in case internal factors such as waste, test failures, rejects or poor performance occur at  unacceptably high levels

Why apply 8D problem solving

Next to a collaborative and consistent way to address production problems, 8D also delivers other benefits including but not limited to:

• developing team-wide skills when it comes to solving production problems
• creating an ongoing record of failures that can inform problem solving efforts to come
• improved understanding of statistical tools leveraged in problem solving
• improved efficiency and effectiveness in team efforts to solve problems
• a better understanding of RCA (Root Cause Analysis)
• developing problem solving skills that can be adapted for other areas/departments in a          company
• enhanced skills when it comes to taking corrective actions
• enhanced collaboration and discussions around problem solving
• enhanced ability by the team to identify where change is needed
• improved management understanding of processes

How to leverage 8D if using quality management software

One of the most effective ways to leverage the 8D method is by applying it using a smart QMS. The cloud-based quality management system from AlisQI was designed to help manufacturers work smarter, not harder. We automate data collection, data analysis, project management and other routine tasks so that manufacturers can focus on continuous improvement.

Within AlisQI manufacturers have a QESH problem-solving page, a standardized dashboard based on the 8D methodology. Whether it’s a complaint, deviation or safety incident, this page provides all the components you need to analyze, follow up on and report production problems. It is available for all QESH processes, no matter their context.

A closer look at the Problem-solving page

The QESH problem-solving page is divided into four sections. Together, they make for an integrated approach to problem solving. To be more specific:

• Incident details This presents all information entered via the form to register or follow up on an incident. The form can be fully tailored. It details tasks leading up to the incident, the damage that occurred as well as immediate actions that have been taken.
• Attachments Uploaded images depicting the incident are shown right away. Other file types are linked and easily accessible. Teams can add just about any file type as an attachment. Typical examples include images, Word, Excel, PPT, or PDF files.
• CAPA actions Shows all connected corrective or preventive actions related to the incident, with their owner, due date, and status. The moment you assign an action, the action owner is informed automatically. The CAPA actions are managed centrally, so you always know who is doing what.
• Root cause analysis The lower right quadrant shows an example of five times why root cause analysis. This allows for a systematic approach to root cause findings.

Additionally, the smart QMS allows for the creation of full-featured 8D reports (including all actions and their status).

Do you want to learn more and actively use 8D problem solving to improve production? Book a free online demo, and we’ll show you how to set up effective QESH management so that you can focus on improving your business.

Otto de Graaf

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