8D analysis presentation

This is very useful presentation on "8D method" for analysis of customer complaint and rejection analysis.

1. 1
-: 8D Problem Solving Technique : -
Prepared By:
Mr. Prashant S. Kshirsagar
B.E.Metallurgist
(Sr.Manager-QA dept.)

2. -: Content :-
Defining 8D
Overview of 8D
Review of 8D steps
Step wise description
of 8D
Benefits of 8D

3. -: What is the Problem? :-

4. -: What is 8D methodology?:-
8D stands for the “8 disciplines” or the 8 critical steps for
solving problems.
It is a highly disciplined and effective scientific approach
for resolving chronic and recurring problems.
It was developed by “US dept. of Defense” (DoD) in 1974
and popularized by “Ford Motor Company”

5. -: Overview of “8D Process” :-

6. -:”0D Or Pre 8D” is called Planning:-

7. -:”0D Or Pre 8D” is called Planning:-
This is the preparation step that needs to be
done before starting the 8D process.


What kind of preparation is done here?
-A deeper understanding of the problem and its history are necessary
for solving the problem.
-Plan your approach
- You need to Consider:
- a) Who will be on your team?
- b) What is your time frame?
- c) What resources will you require?
- d) Is it a new problem? Is it chronic/continuing?
- e) Has it occurred before?
- f) What is the history of the problem?
- g) How was it solved before?

8. -:Discipline 1: Establish the team:-
This discipline is very important as the 8D is based
on the foundation of team synergy. This first
discipline will establish a small group of people with
the process/product knowledge, allocated time,
authority and skill in the required technical expertise
to solve the problem and implement corrective actions.

People from Multidisciplinary – that’s mean person with different
department: It comprises of 4 to 8 people who are closely related to the
problem A) Engineers (designers) B) Technologists (production) C) Rework
operator, production staffs (often have the biggest experience) D) Quality
Engineers E) Buyers F) Others

Why is team approach important?
• A team can perform more effectively than individuals to solve problems.
• A group of people can communicate and think creatively.
• Brainstorming as a group can stimulate ideas giving the team a better
perspective of the problem.

9. -:Discipline 1: Establish the team:-
Who should be on the 8D team and their
responsibilities?

•Champion (i.e. an executive sponsor
not a working team member) that is
ultimately responsible for fixing the
problem.

•Team Leader (i.e. Quality engineering or Product Manager) -
The person who coordinates the entire 8D project through-out all of its
disciplines. Scheduling periodic meetings. Makes sure the team is on
track and all team members are working together to resolve the
problem.

•Team members must complete their responsibilities & actions and
report back to the team leader for further progress.

10. -:Discipline 2: Describe the Problem:-
This is the stage where you need to most accurately describe the
problem. Properly problem description is the starting point to
further step of analysis and proper understanding of the nature
of the problem for the Team as well as people from outside.

11. -:Discipline 3: Containment action:-
Example of an interim containment actions are:
• Stoppage of production / shipment
• Additional visual control
• Informing the Customer about the problem (for verification
of the goods at the Customer.)
• Segregation goods on OK / NOK
• Informing operators about the problem
An interim containment action means:
A “Band-Aid” is put in place to
prevent the effect of the problem
from impacting customers and/or
employees while a permanent
solution is being developed and
implemented.

12. -:Discipline 4: Root Cause analysis:-
Defining the root causes of a problem is the core of the 8D problem-
solving process. This is normally the toughest aspect of the problem-
solving process

•Tools to be used for finding root cause:
1) Pareto Charts 2) Affinity Diagram 3) Brainstorming Session 4) 5-Whys
Process 5) Fishbone Diagram 6) Fault Tree Analysis 7) Statistical Analysis
8) ANOVA 9) DOE 10) Regression Analysis 11) Hypothesis Testing
12) GR&R 13) Flow Charts 14) Audits 15) FMEA

13. -:Discipline 4: Root Cause analysis:-

14. -:Discipline 5: Permanent Corrective Actions:-
The Team determine which actions/
solution should be introduced in the
short period of time to ensure that the
process/product is controlled & will
make the problem go away without
leading into other unwanted issues.
Criteria for choosing the best solution:
•Practical - The 8D team should be able to implement the solution
practically.
•Feasible - The solution must be feasible.
•Cost effective - Implementing and using the solution must be cost
effective.
•Robust - The solution shouldn’t fail when used in production.
Robustness of the solution is an essential characteristic (error proofing,
impact-effort matrix)
•Team Champion must have full buy-in to PCA’s and facilitate their
implementation.

15. -:Discipline 5: Permanent Corrective Actions:-
Examples of PCA’s:
• Introducing additional
control in process
• Introducing additional other
process (e.g. component
reworked, test corrected)
• Rework defective units found
inside
• Rework units returned from
Customer
• Inform the Supplier about
defective part delivered and their
Exchange, etc.

16. -: Discipline 6: Implement PCA’s:-
•Ensure that everyone in the group follows the action plans
•Make a status of the action plan which would contain
actions to get new tools, to provide training and to
write/update applicable documented procedure.
•Begin tracking results.

Tools to Use : You can use the following tools to accomplish:
• Check sheets
• Run charts
• Control charts
Once the solution and its implementation are
approved, the next step is to create an Action Plan.
The Action Plan outlines what steps are needed to
implement the solution, who will do them, and
when they will be completed.

17. -: Discipline 6: Validate PCA’s:-
Please verify that the
corrective actions taken are
efficiently. It should be
based on " Real Data" from
the process. Action should
not be estimated on the basis
of only the same opinion of
the persons interested
Examples:
• Less reject % (ppm) in process.
• Test / control results shows improvement.
• Engineering’s measurements (dimension, units appearance ) are
correct (according to tolerance, specification).
• Other proofs shows on Introducing corrective action.
• Supplier delivers goods of better quality.

18. -: Discipline 7: Prevent Re-occurrence:-
Next step is to determine what action should be
taken to prevent recurrence of the problem.
Preventing recurrence is an important part of a
problem’s solution. To prevent recurrence of the
problem, the team must verify that the outcome
of their Action Plan works and on-target.
Tools to be used:
1) Control charts 2) Control plans 3) Histogram
4) Capability Analysis 5) FMEA 6) GR&R
Examples:
• Modified or make proper jig (tooling).
• Changing the process parameters in order to prevent defects.
• Changing process / tools by Supplier which make parts.
• Changing procedures (organization change).
• Changing documentation / specification (if was incorrect).
• Preparing systematic and full training for staff.

19. -: Discipline 8: Recognize the Team:-
Once a team has completed implementing the
solution and ensured that the solution works, all
team members deserve to be congratulated.
Team members need to know that their efforts
are appreciated and that the organization knows
about their accomplishments.
Once the problem has been resolved, the team should publish and
release a final report along with lessons learned.
 The 8D report gives a quick snapshot of what was done in the
project and categorizes them under the 8 Disciplines.
The report serves as a communication tool showing overall progress
of the 8D project along with actions taken.
 Also, a very useful tool to share is the "Lessons Learned" and
project findings.
 Completed 8Ds to be posted on the shared quality site (under 8D
reports).

20. -:Benefits of 8D:-