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LSS - 8D Basics

The document provides information on the 8D problem solving process, including: - The 8D process was developed at Ford Motor Company and is commonly used in automotive and other industries to identify, correct, and eliminate recurring problems. - It consists of 8 steps (originally 9) to systematically establish the problem, determine the root cause, implement corrective actions, and prevent future occurrences. - The benefits include improved problem solving skills, a database of lessons learned, and more effective implementation of changes to address issues.

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72 views

LSS - 8D Basics

The document provides information on the 8D problem solving process, including: - The 8D process was developed at Ford Motor Company and is commonly used in automotive and other industries to identify, correct, and eliminate recurring problems. - It consists of 8 steps (originally 9) to systematically establish the problem, determine the root cause, implement corrective actions, and prevent future occurrences. - The benefits include improved problem solving skills, a database of lessons learned, and more effective implementation of changes to address issues.

Uploaded by

schmom
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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WELCOMES YOU ALL

8D Basics
8D Problem Solving Approach

Information Source:
https://asq.org/quality-resources/eight-disciplines-8d
https://www.operational-excellence-consulting.com/
https://quality-one.com/8d/
Own research and experience

Creating Value through Process & People Development + 91 9589004005 | [email protected] | www. ekpahlakadam. com
History of 8D Problem Solving

The U.S. government first standardized the 8D Problem Solving Process during the Second World War, referring to it as
Military Standard 1520. It was later improved and popularized by the Ford Motor Company in the early '90s.

Ford's Powertrain Organization (transmissions, chassis, engines) wanted a methodology where their manufacturing
teams could work on recurring chronic problems.

In 1986, the assignment was given to develop a manual and a subsequent course that would achieve a new approach to
solving identified engineering design and manufacturing problems.

The manual for this methodology was documented and defined as Team Oriented Problem Solving (TOPS), first published
in 1987.

The manual and subsequent course material were piloted at Ford World Headquarters in Dearborn, Michigan.

The Ford 8Ds manual is extensive and covers chapter by chapter, how to go about addressing, quantifying, and resolving
engineering issues.

EK Pahla Kadam, Management Consulting 2 Dinesh Sharma│[email protected] │ +91 9589004005


History of 8D Problem Solving

In the late 1990s, Ford developed a revised version of the 8D process that they call "Global 8D" (G8D), which is the
current global standard for Ford and many other companies in the automotive supply chain. The major revisions to the
process are as follows:
✓ Addition of a D0 (D-Zero) step as a gateway to the process.
✓ At D0, the team documents the symptoms that initiated the effort along with any emergency response actions (ERAs)
that were taken before formal initiation of the G8D.
✓ D0 also incorporates standard assessing questions meant to determine whether a full G8D is required. The assessing
questions are meant to ensure that in a world of limited problem-solving resources, the efforts required for a full team-
based problem-solving effort are limited to those problems that warrant these resources.
✓ Addition of the notion of escape points to D4 through D6. An 'escape point' is the earliest control point in the control
system following the root cause of a problem that should have detected that problem but failed to do so. The idea
here is to consider not only the root cause, but also what went wrong with the control system in allowing this problem
to escape.
✓ Global 8D requires the team to identify and verify an escape point at D4. Then, through D5 and D6, the process requires
the team to choose, verify, implement, and validate permanent corrective actions to address the escape point.

EK Pahla Kadam, Management Consulting 3 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Basics

Eight disciplines problem solving(8Ds) is a method developed at Ford Motor Company.

It is typically employed by quality engineers or other professionals and is one of the most commonly used in the
automotive industry.

It has also been successfully applied in healthcare, retail, finance, government, and manufacturing.

The purpose of the 8D methodology is to identify, correct, and eliminate recurring problems, making it useful in product
and process improvement.

✓ The 8D problem solving model establishes a permanent corrective action based on statistical analysis of
the problem and focuses on the origin of the problem by determining its root causes.

✓ Although it originally comprised eight stages, or disciplines, the eight disciplines system was later
augmented by an initial planning stage.

EK Pahla Kadam, Management Consulting 4 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Basics

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

EK Pahla Kadam, Management Consulting 5 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Basics

Benefits of 8D Problem Solving Process:


✓ 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 & 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)
✓ 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

EK Pahla Kadam, Management Consulting 6 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Basics

8D Problem Solving Steps

D0: Planning and preparatory work

D1: Establish the team

D2: Define and describe the problem

D3: Develop interim containment plan; implement and verify interim actions

D4: Determine, identify, and verify root causes and escape points

D5: Choose and verify permanent corrections (PCs) for problem/nonconformity

D6: Implement and validate corrective actions

D7: Take Preventive measures to prevent recurrence

D8: Recognize team and their contribution

EK Pahla Kadam, Management Consulting 7 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D1 - Establish the Team:


Establish a small group of people with the process and/or product knowledge, allocated time, authority,
and skills in the required technical disciplines to solve the problem and implement corrective actions.
Key Deliverables include:
✓ Review the problem or improvement opportunity
✓ Review priorities, scope, and complexity
✓ Identify if a team is needed
✓ Identify team members and establish the team
✓ Nominate a team leader and project champion
✓ Establish basic team guidelines
✓ Consider team-building exercises

EK Pahla Kadam, Management Consulting 8 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D2 - Describe the Problem:


Describe the internal or external problem by identifying “what is wrong with what” and detailing the
problem in quantifiable terms. Develop a clear problem statement and problem description.
✓ Develop a Problem Statement
✓ Develop a Problem Description using the “IS – IS NOT Matrix”
✓ Develop a flowchart of the process and identify critical process steps with respect to the Problem
Description
✓ Develop a Fishbone Diagram or Process Variables Map to identify possible causes?
✓ Determine whether this problem describes a “something changed” or a “never been there” situation
✓ Establish a high-level project plan, including milestones, project goals, and objectives

EK Pahla Kadam, Management Consulting 9 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D3 - Develop Interim Containment Actions:


Define, verify and implement interim containment action to isolate the effects of the problem from any
internal and/or external Customer until permanent corrective (preventive) actions are implemented.
✓ Define potential Interim Containment Action
✓ Verify the effectiveness of potential Interim Containment Action
✓ Select and implement Interim Containment Action
✓ Validate the effectiveness of implemented Interim Containment Action with the Customer

EK Pahla Kadam, Management Consulting 10 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D4 - Define and Verify Root Cause(s) and Escape Point(s):


Isolate and verify the root cause by testing each root cause theory against the problem description and
test data. Isolate and verify the place in the process where the effect of the root cause could have been
detected and contained but was not (escape point).
✓ Establish any additional data collection plans needed to learn more about the problem and/or
possible causes
✓ Utilize the Fishbone Diagram or Process Variables Map created earlier to identify the most likely
cause(s)
✓ Isolate and verify the most likely cause(s) by testing each Root Cause Theory against the Problem
Description and the collected data
✓ Isolate and verify the place in the process where the effect of the root cause could have been
detected and contained but was not (escape point)

EK Pahla Kadam, Management Consulting 11 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D5 - Choose and Verify Permanent Corrective Actions:


Select the best permanent corrective actions to remove the root cause and to address the escape point
in the process. Verify that both decisions will be successful when implemented and not cause any
undesirable effects.
✓ Develop solution(s) to remove the root cause(s)
✓ Develop solution(s) to address the escape point(s)
✓ Select the best solution(s) to remove the root cause(s)
✓ Select the best solution(s) to address the escape point(s)
✓ Verify that effectiveness of the selected solutions
✓ Verify that selected solutions do not cause undesirable effects

EK Pahla Kadam, Management Consulting 12 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D6 - Implement and Validate Permanent Corrective Actions:


Plan and implement selected permanent corrective actions, remove the interim containment action.
Monitor long-term results.
✓ Implement the best solution(s) to remove the root cause(s)
✓ Implement the best solution(s) to address the escape point(s)
✓ Validate the effectiveness of the implemented solutions from the Customer perspective
✓ Monitor the effectiveness of the implemented solutions and assure that they do not cause any
undesirable effects
✓ Remove Interim Containment Action

EK Pahla Kadam, Management Consulting 13 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D7 - Take Preventive Measures to Prevent Recurrence:


Modify the necessary systems, including policies, methods, and procedures, to prevent recurrence of
the problem and similar ones.
✓ Identify opportunities to improve and standardize systems, policies, methods, and procedures for the
present problem
✓ Identify opportunities to improve and standardize systems, policies, methods, and procedures for
similar problems

EK Pahla Kadam, Management Consulting 14 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Steps

D8 - Recognize Team and Their Contribution:


Complete the team experience and sincerely recognize both team and individual contributions.
Celebrate success and identify lessons learned.
✓ Perform a final review of the problem-solving project
✓ Finalize and archive project documentation
✓ Recognize the team’s success and individual contributions
✓ Capture lessons learned and integrate findings into the 8D Problem Solving Process
✓ Reward and celebrate

EK Pahla Kadam, Management Consulting 15 Dinesh Sharma│[email protected] │ +91 9589004005


8D Problem Solving Main Tools

Following are the basic problem-solving tools


✓ Pareto Chart
✓ Why-Why Analysis
✓ Process Flow Charting
✓ Is/Is Not Analysis
✓ Fishbone Diagram
✓ Process Variables Mapping
✓ Comparative Analysis,
✓ Root Cause Verification
✓ Process Control Plans
Many other tools are also used based on need, i.e. 7 QC Tools, 7 Management and Planning Tools.

EK Pahla Kadam, Management Consulting 16 Dinesh Sharma│[email protected] │ +91 9589004005


Thank You

[email protected] ekpahklakadam.com

EK PAHLA KADAM +91 9589004005 Gurugram, Haryana

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