8D-Guide

8D (EIGHT DISCIPLINES) PROBLEM SOLVING PROCESS The 8D Problem Solving Process is used to identify, correct and eliminate the recurrence of quality problems. 8D is a problem-solving methodology for product and process improvement. It is structured into eight disciplines, emphasising team synergy. The team as whole is better and smarter than the quality sum of the individuals. Each discipline is supported by a checklist of assessment questions, such as what is wrong with what, what, when, where, how much. 8D (Eight Disciplines) Problem Solving Process 1. Use Team Approach Establish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group must select a team leader. 2. Describe the Problem Describe the problem in measurable terms. Specify the internal or external customer problem by describing it in specific terms. 3. Implement and Verify Short-Term Corrective Actions Define and implement those intermediate actions that will protect the customer from the problem until permanent corrective action is implemented. Verify with data the effectiveness of these actions. 4. Define end Verify Root Causes Identify all potential causes which could explain why the problem occurred. Test each potential cause against the problem description and data. Identify alternative corrective actions to eliminate root cause. 5. Verify Corrective Actions Confirm that the selected corrective actions will resolve the problem for the customer and will not cause undesirable side effects. Define other actions, if necessary, based on potential severity of problem. 6. Implement Permanent Corrective Actions Define and implement the permanent corrective actions needed. Choose on-going controls to insure the root cause is eliminated. Once in production, monitor the long-term effects and implement additional controls as necessary. 7. Prevent Recurrence Modify specifications, update training, review work flow, improve practices and procedures to prevent recurrence of this and all similar problems. 8. Congratulate Your Team Recognize the collective efforts of your team. Publicise your achievement. Share your knowledge and learning.

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8D Report Ref No: Sample General Information Title: Status: Type: Customer Ref:

Customers description Open/Closed Quality Customer/Reject Number

Organisation: Opened Date: Closed Date: Last Update:

Supplier Date informed By Customer Last actioned

By:

Author

D0 – Symptom Symptom (1 of 1 ):

Effect experienced by Customer

Description/Qualification:

Describe the effect in detail in terms the customer can understand

D0 – Emergency Response Action (ERA) ERA (1 of 1 ): Description:

Is ERA required YES/NO

Implemented

Description of ERA or reason why team did not instigate – example all product quarantined, 100% inspect prior to ship?

Yes/No?

Removed Yes/No?

D1 – Team Name Name only required

Role Champion Team Leader Team Members

Telephone Contact number

E-mail E-mail address

D2 - Problem Description Statement: Description:

A simple statement derived from ‘What is Wrong with What’ What: What is it – Description, Type, Part Number, Serial Number etc? When: What date was it first seen/reported? Where: Where it was first reported? Customer premises, On receipt, In-process, during test etc. How Big How many – 4 out of 20, all products, One isolated incident?

D3 – Interim Containment Action (ICA) ICA (1 of 1 ):

What has been done to ensure continuance of shipped parts to the customer?

Description: A description on how parts are being controlled and the method whereby this is verified and how good stock is identified. E.g. – ‘x’ number of parts visually inspected against criteria of reported defect, by trained inspection personnel prior to release for shipment. These parts identified by label on outer box stating – 100% inspected and verified OK stock.

Verified Verification Description:

Validation Description:

Implemented Date ICA put in place

Validated Date ICA validated

Removed Date ICA removed

How has the containment action been verified? Does the defined inspection method work, is it effective and could it be maintained long term whilst a permanent fix has been put in place. Has customer approved the containment action?

How has the containment action been validated?

Have we identified what could go wrong with the plan and have preventive and contingency actions been considered?

D4 – Root Cause ( 1 of ): Description

a. Is there a root cause (a single verified reason that accounts for the problem)? b. Is there more than one potential root cause? c. What factor(s) changed to create this problem? What data is available that indicates any problem in the manufacturing or process design? d. Does each item on the potential root-cause list account for all known data? Has each item been verified (used to make the effect come and go)? e. How did we verify this root cause? d. Does this root cause explain all the facts compiled at D2? f. Has the root-cause analysis gone far enough (do we need to know why this root cause happened)? g. How did you determine assignment of percent contribution? h. Combined, do the items on the potential root-cause list account for 100 percent of the problem (is the desired performance level achievable)?

Date Verified:

Date verified

% contribution:

All one cause?

Verification Description:

D5/D6 – Permanent Corrective Actions (PCA) Root Cause PCA (1 of 2 ): Description: Description of method and actions used to introduce Permanent Corrective Action(s) a. What criteria have been established for choosing a PCA for the root cause and escape point? b. What choices have been considered for the PCA's? c. Have we overlooked better choices? d. Do we have the right experience on this team to make this decision? e. What risks are associated with this decision and how should they be managed? f. What are the possibilities that this choice, once implemented, will create other troubles? g. Can our customer live with this resolution? h. Will our containment continue to be effective until our choice can be implemented? i. What resources will be required for PCA implementation? Do we have these resources? j. What departments will need to be involved in the planning and implementation of this decision?

Date Verified

Date Implemented

Date Validated

Verification of root cause supported by documented evidence, data or visual reproduction OK/NOK parts

Verification Description:

a. What evidence (proof) do we have that this will resolve the problem at the rootcause level? b. Did our verification methods make allowances for variations in the frequency (or patterns) created by the cause? c. Which variables did we measure during the verification step? Do these indicators constitute sound verification?

Validation Description:

Description of method used to validate effectiveness of elimination of the root cause of the problem

D4 – Associated Escape Point Description: a. Does a control system exist to detect the problem? b. Has the current control system been identified? Does this control system represent a change from the original design? c. Has it been verified that the control system is capable of detecting the problem? d. Is the identified control point closest to the root cause/potential root cause? e. Is there a need to improve the control system? Date Verified: Verification Description: Description of how escape point was verified: a. What evidence (proof) do we have that this will resolve the problem at the root-cause level? b. Did our verification methods make allowances for variations in the frequency (or patterns) created by the cause? c. Which variables did we measure during the verification step? Do these indicators constitute sound verification?

D7 – Prevent Recurrence Actions (PRA) Root Cause PRA (1 of ): Description; Have all changes been documented (FMEA, control plan, process flow, Inspection criteria)? What actions have been taken to correct similar operations or processes that may exhibit similar problem areas?

Implemented:

Date

D7 – Systemic Prevent Recommendation(s) Responsible Organisation: Recommendation ( 1 of ):

Person / Department FMEA, Control Plan, Work Instruction etc Process Flow Work Instruction etc

Date Created:

D8 – Recognise Team and Individual Contributions Author: Recognition:

Date: Who: When: How:

Authorisation for Closure Name

Signature

Mandatory to close

Date

Customer Supplier Other

As specified

Attachments Description Documents which provide supporting verification and Validation. Inspection Reports, FMEA’s Control Plans SPC charts, Cpk data. Photographic evidence. Action Plans, Timelines, etc

File Name

THIS INFORMATION MAY BE EMBEDDED

Additional Information

Attached By

Date Attached