8D (Eight Disciplines)

Problem Solving Methodology

SBL HRDF claimable

There is an increasing awareness that problem solving skill among employees is an important and essential critical skill
for company success and to remain viable in today’s very competitive environment. The 8D (Eight Disciplines)
Problem Solving Methodology is a step-by-step problem solving methodology pioneered by Ford Motor Company TRAINER PROFILE - TED TAN SWEE HUA
through its Team Oriented Problem Solving Global 8D Process. It is a highly effective approach to finding root causes, Ted Tan has a total of 18 years of experience in semicon-
development of proper actions to eliminate root causes, and implementation of permanent corrective action. ductor manufacturing fields. He holds a B (Sc) Electrical
Engineering ( University of Michigan, US) .
Problem Solving Process and Models
The 8D process uses a combination of effective tech- He started his career with Motorola Semiconductor
The 8D Approach to Problem Solving
niques and tools to focus a cross functional team Malaysia as an equipment engineer from 1990 to 1995. In
Corrective Action / Preventive Action and 8D Method his role as a equipment engineer, he worked extensively
through a very detailed analysis of the problem. When
followed diligently, 8D will lead to the discovery of the The Problem Encountered while Implementing 8D on a project to integrate product tester to manufacturing
root causes and possible solutions with consideration  8D Checklist • 8D Examples / Ten Actions Verbs process equipments to check on product functionality.
of cost, timing, effect on customers, and the impact on
 The Management Cycle of Verification & Validation
He was later promoted to Senior equipment engineer in
charge of overall front-end process equipment mainte-

the organisation.
Example of Good 8D Reporting nance activities.
The workforce’s improved capability to 8D Method
problem-solving is a necessary requirement in Zero
 Example of Bad 8D Reporting Workshop Exercise From 1999 to 2008, with response to zero customer
Defect (ZD), 6 Sigma, FMEA, ISO/TS 16949, ISO 9001, incident initiative, Ted was was in charge of process
TQM and Lean Manufacturing. 2) DETAILED EXPLANATION OF THE 8D PROCESS engineering in addition to his equipment responsibilities.
D0 : Preparing for the 8D Process In this new role, he implemented in- process quality
In this 2-day practical workshop, participants will learn - Define & Quantify Symptom inspections for all the products in QFP backend assembly
through a step by step instructional process of prepara- operations. These in-process quality inspections were
- Identify Customer & Affected Parties
tion, establishing a team, brainstorming, to systemati- part of quality control (QC) based on Six Sigma method-
- Determine Emergency Response Action (ERA)
cally analysing and preventing problems from recurring. ology using Statistical Process Control with CPK & X bar R
In addition, participants will learn the practical problem D1 : Establishing the Team
charts to control molding and trim & form processes.
solving tools required by the 8D process. Through the - Group Problem Solving
workshop, participants will be able to appreciate why D2 : Describing the Problem In his equipment responsibility, he was in charge of
implementing and using an 8D problem solving method- - Problem Statement preventive maintenance of all metrology systems in the
ology using a multi-disciplined team is beneficial and - Object, Concern, & Quantification QFP back-end operations. Perform gauge GR&R, bias,
important, especially when meeting customer expecta- - Develop Interim Containment Action (ICA) discrimination, linearity & stability studies to ensure the
tions. D3 : Define Root Cause metrology system’s integrity. He participated in the
- Develop Interim Containment Action (ICA) following yield improvement projects:
Participants will also learn why implementing and using - Validation of 'Permanent Corrective Action'
- Verification & Validation of 'Interim Containment Action' * Implemented AutoMark software system to reduce
an 8-D problem solving methodology by using a multi-
disciplined team is beneficial and important, especially material scrap due to wrong marking on product caused
D4: Define/ Verify the Root Cause / Escape Point
when meeting customer expectations. Participants will - Cause & Effect Analysis by system and/or human error.
learn through a step by step instructional process of; - Verification of Root Cause
* Applied problem solving methodology to reduce
preparation, establish a team, brainstorming, to system-
D5 : Choose the Corrective Action & Verify mechanical defects.
atically analyze and prevent problems from recurring.
- Verify the Permanent Corrective Actions (PCA) for
Root Cause& Escape Point Involved in Environment Preferred Product (EPP) project to
TARGET AUDIENCE
- Mistake Proofing implement a fool proof system to safe guard misprocessing of
For anyone who wishes to acquire the skills using sys- D6: Implement & Validate Permanent Corrective Lead-Free and non Lead-Free products.
tematic approach to solve problems. Cross-functional Actions (PCAs) He later was appointed as the departmental champion for
- Validation of 'Permanent Corrective Action' Error Proofing to co-ordinate Poka Yoke activity & training for
project team leaders & members from both the manu-
facturing & service sectors including oil & gas, electron- D7: Prevent Recurrence QFP Assembly Operations. As part of Process Change En-
ics, transportation, telecommunication, banking & - Standard Operating Procedures hancement (PCE), Ted championed the Piece Part Validation
finance, logistics, healthcare, government, public ser- - Poka-Yoke (Mistake Proofing) project at back-end operation utilizing the Shop Floor Control
vice, etc. (SFC) software to validate correct piece part being used in
D8 : Recognise Contributions of the Team & Individuals mold process.
COURSE OBJECTIVES - Recognition Methods

 Understand & use the 8D process to solve prob- 3) WORKSHOP ON PREPARING AN EFFECTIVE 8D REPORT He also deployed mold compound part number, thaw time
lems and floor life expiry validation for mold process. For trim &

 FREE BONUSSES form process, Ted implemented the machine to product/

Have an understanding of the practical applica- package validation to ensure correct product/package type
#1: Just for You - A Subliminal CD to Generate Creativity
tion of the supporting tools required for successful Instantly & Effortlessly! was processed at the designated machines to eliminate mis-
problem resolution processing of production materials in machine not configured
 Apply the appropriate problem-solving tools #2: A subliminal CD on Hypnotherapy for Inner Peace by for the product/package type. Other projects include Elec-
tronic Positrol log, Interactive Out Of Control Plan (OCAP) &
throughout the problem solving process Julie Dittmar (USA) to control stress while you sleep! An
excellent tool to combat stress & work fatigue. Disaster Recovery Plan.

COURSE OUTLINE Ted is an excellent trainer, having conducted many training

#3: An EBOOK on Mind Power Exercises, Visualization &
1) INTRODUCTION TO THE 8D PROCESS Creative Games. programs for Motorola. He is able to take a complex subject &
Introduction to 8D make it easy to understand. The technique he teaches are
The 8D Process Flow practical & readily applicable at the workplace based on his 18
 The Flow of Countermeasures
#4: A MIND MOVIE to enhance success, creativity & peak
performance at the workplace. Getting results desired &
years experience working in semiconductor manufacturing
 Types of Countermeasures achieving health goals effortlessly, easily & successfully
field a top engineer. His qualifications, work experience,
technical & management background & expertise makes him
The 8D Report Format where believing in yourself matters an extremely capable trainer.
Problem Definition & Perception

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