8d problem solving Tool for manufacturing.ppt

8d problem solving Tool for manufacturing

1. 1
8D Approach to Problem-Solving
Trainer : PARABAKARAN
8D Approach to Problem-Solving

2. 2121
STST
CENTURY: GLOBAL COMPETITION CENTURY: GLOBAL COMPETITION
The globalization of trade has exposes
local industries to new Competitive
pressures.
Old View: Cost + Profit = Price
New View: Price – Profit = Target Cost
Order Qualifiers in a Global Market:
Superior Quality, Competitively Priced, Quick Delivery
Order Winners in a Global Market:
Products and Services that are valued by the customer.

3. The 8D method provides
you with an in-depth
understanding of
analyzing problems to
identify the root causes.
The eight-discipline (8D) Approach to Problem-
Solving is a systematic approach to problem-solving
& documenting of results, developed by Ford Motor
Co. It is an essential step to process improvement.
8D Approach to Problem-Solving

4. CONTINOUS IMPROVEMENTCONTINOUS IMPROVEMENT = = KAIZEN KAIZEN
IMPROVEMENT IMPROVEMENT
WITHOUT WITHOUT
ENDINGENDING
In Japanese,
KAI
Change
ZEN
Good
KAI ZEN=
Change for
better
The Small, gradual, incremental changes over a long period
that adds up for a major impact on business in the future.
Qualifiers of 21st Century & Skills

5. To use the 8D methodology to describe steps to
solve a problem. To implement necessary Tools
using the 8D methodology.
8D Approach to Problem-Solving
To participate in an 8D team
to improve the communication
and documentation of the
problem.
To apply the technique in
daily work problems
Class outlines:

6. 8D Approach to Problem-Solving

7. It will strengthen your
understanding on;
what is 8D,
 why Apply 8D,
 when to Apply 8D &
 how to Apply 8D at work.
This workshop provides you with a working
knowledge of 8D effective root cause analysis
and tools to address non conformity.
8D Approach to Problem-Solving
BENEFITS BENEFITS

8. 8D Approach to Problem-Solving

9. Introduction to 8D
The 8D Process
The 8D Report Format
The 8D Approach
1D: Use team approach
2D: Describe the problem
3D: Implement and verify containment action
4D: Find root cause
5D: Corrective action plan
6D: Preventive action plan
7D: Verify Corrective Action/Preventive Action
8D: Congratulate your team
Corrective & Preventive Action - Guidelines
Contents:
8D Approach to Problem-Solving

10. Introduction
What is Problem Solving?
 The 8D Process
Why use a structured
process?
 The 8D Report Format
8D format
 
 
The 8D Approach
Prepare for the Process
Getting started
 Problem selection
 Pareto charts
 
   
8D Approach to Problem-Solving
D1 Use a Team Approach
Team selection and makeup
Exercise: Form teams, design a check sheet to collect
data and perform initial data collection run
 
 
D2 Describe the Problem
The importance of collecting and interpreting data
 Problem statements and operational definitions
 Flow charts
 Exercise: 
Use an IS/IS NOT worksheet to develop
problem definition
 
  
D3 Implement and Verify Containment Activity
Containment strategies -Thinking outside the box
Problems with containment
Exercise: 
Identify possible containment strategies
 
 
Morning

11. D4 Define Root Cause
Root cause analysis methodology
Structured brainstorming techniques
Cause and Effect (Fishbone)
Diagrams
Repeated Whys (5 Whys)
Cause of Occurrence vs. Cause of
Escape
Exercise: Use structured
brainstorming methods, and
a
 fishbone diagram to identify and
classify possible root causes
 
  
8D Approach to Problem-Solving
Exercise: Design a simple experiment to isolate
root cause
 Run Charts
 Exercise: Construct a run chart
 
D5 Develop Permanent Corrective Actions
Developing an Action Plan
Error Proofing (Poka Yoke)
Nominal Group Technique
 Exercise: 
Use NGT to reach consensus on
Corrective actions - develop PCAs
 
Noon

12.  
 
Value Stream Mapping (VSM)
Control Charts and Basics Concepts
of SPC
Process Capability
 
 D8
 Congratulate Your Team
 
 
8D Auditing
 Summary and Wrap-up
8D Approach to Problem-Solving
D6 Implement and Verify Corrective Actions
Putting the Action Plan into place
Action Matrix
Force Field Analysis
Histograms
 
Scatter diagrams
 Exercise: 
use a scatter diagram
D7
 Prevent Recurrence
Identifying recurrence issues
Leveraging your success for maximum ROI
 
  
Noon

13. WHAT DOES THE WORD ‘WHAT DOES THE WORD ‘ QUALITY’ QUALITY’ MEANS TO MEANS TO
YOU ? YOU ?
Delighting .. 1
st
meet, then exceed and 3
rd
make you happy!
8D Approach to Problem-Solving

14. QUALITYQUALITY PLAYS A MAJOR ROLE IN TODAY’S PLAYS A MAJOR ROLE IN TODAY’S
MANUFACTURING ENVIRONMENT.MANUFACTURING ENVIRONMENT.
Understanding Customer
needs and monitoring
process behaviors and
variation to safe guard
Customer from receiving
a defect is key in assuring
Quality.
Superior Quality, reduce Cost
and on-time Delivery (QCD)
8D Approach to Problem-Solving

15. It is also referred to as
“Eight Steps Plan”,
“TOPS” (Team Oriented
Problem-Solving) or
“Post-Mortem”.
8D Problem-Solving is a powerful problem-solving
technique to resolve and eliminate chronic or
problematic issues.
8D Approach to Problem-Solving
INTRODUCTIONINTRODUCTION

16. 8D Approach to Problem-Solving
What is Problem Solving? 
Problem solving
 is the act of;
defining a
 problem,
determining the cause of

the
 problem,
 identifying, prioritizing,
 selecting alternatives for
a solution &
 implementing a solution.

17. 8D Approach to Problem-Solving

18. The 8D Process
8D Approach to Problem-Solving
The 8D is a problem solving methodology designed to
find the root cause, devise short-term fix & implement
long-term solution to prevent recurrence.
When your product is
defective or do not satisfy
your customers, an 8D is
an excellent first step to
improving Quality and
Reliability.

19. 8D Approach to Problem-Solving

20. 8D Approach to Problem-Solving
The 8D Report or 8D corrective action report is a problem-
solving approach for product and process improvement.
8D Methodology is used
to implement structural
long-term solutions to
prevent recurring
problems.

21. 8D Approach to Problem-Solving
The 8D Report was first used in the FORD automotive
industry. During World War II, the 8D Method was used
in Team Oriented Problem Solving (TOPS) in the
United States under Military Standard 1520.
It was later used and
popularized by car
manufacturer
 
Ford.

22. FORD AUTOMOTIVE INDUSTRY FOR FORD AUTOMOTIVE INDUSTRY FOR
STANDARDIZATIONSTANDARDIZATION
•Assembly line - Henry Ford 1920sAssembly line - Henry Ford 1920s
•Low skilled labor, simplistic jobs, no pride in workLow skilled labor, simplistic jobs, no pride in work
•Interchangeable partsInterchangeable parts
•Lower qualityLower quality
•Affordably priced for the average familyAffordably priced for the average family
•Billions produced – all identical “ You can choose Billions produced – all identical “ You can choose
any color as long as its Black ”any color as long as its Black ”

23. The 8D Process
8D Approach to Problem-Solving
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.

24. 8D Approach to Problem-Solving
The 8D Approach 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.

25. Why use a structured process?
8D Approach to Problem-Solving
8D methodology offers a consistent, easy-to-learn and
thorough approach to solve any problems, arising at
various stages in production.
You can expect the following
benefits:
Improved team oriented
problem solving skills
Increased familiarity with a
structure for problem solving

26. 8D Approach to 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 for problem solving
Improved problem solving effectiveness and efficiency
Understanding of
 
Root Cause Analysis (RCA)
 Adoption of Problem solving effort & methods into the
organization processes

27. 8D Approach to Problem-Solving
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 and efficiency at
problem solving

28. 8D Approach to Problem-Solving
How to Apply 8D Problem Solving
The 8D process alternates inductive and deductive
problem solving tools to relentlessly move forward toward
a solution.
The Quality-One approach
 individual core team of three for
inductive activities with data
driven tools.
Subject Matter Expert (SME) group
 deductive activities through
brainstorming, data-gathering
and experimentation.

29.  The 8D Report Format What is a 8D Report? 
8D Approach to Problem-Solving
Today, 8D Report is a formal
‘working and thinking method
report’ for smaller problems.
A structured format is used to
document all the 8 disciplines
known as:
 
Global 8D,
 Ford
8D
 
or
 
TOPS 8D.
In the 1990s Ford continued to develop the 8D process
from its origin in the automotive industry.
8D
 FORMAT

30. The 8D Approach
8D Approach to Problem-Solving
1D: Define the Team
2D: Describe the problem
3D: Implement containment action
4D: Define & Verify root cause
5D: Corrective action plan
6D: Preventive action plan
7D: Verify Corrective / Preventive Action
8D: Congratulate your team
Prepare for the Process, Getting started,
 Problem
selection and
 Pareto charts

31. 8D Approach to Problem-Solving

32. 8D Approach to Problem-Solving
The 8D problem solving process is required when:
When to Apply (8D) of Problem Solving
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

33. 8D Approach to Problem-Solving
How to Apply 8D Problem Solving
The 8D process alternates inductive and deductive
problem solving tools to relentlessly move towards a
solution. Use….
The Quality-One approach
 individual core team of three for
inductive activities with data
driven tools.
Subject Matter Expert (SME) group
 deductive activities through
brainstorming, data-gathering
and experimentation.
8D
 FORMAT

34. 8D Approach to Problem-Solving
Inductive reasoning
-draw a general conclusion (making a conjecture)
from repeated observations of specific examples.
The conjecture may or may not be true.
 
Deductive 
reasoning
is characterized by applying general principles to
specific examples.

35. Prepare and Plan for the 8D
8D Approach to Problem-Solving
Before 8D analysis begins, always ask an expert first
for impressions, feedback with the following criteria
applied before 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), to protect

the customer from further
undesired symptoms
8D
 FORMAT

36. 8D Approach to Problem-Solving
D1 Use a Team Approach Team selection and makeup
Exercise:
Form teams,
design a check sheet to
collect data and
 perform initial data
collection run

37. 8D Approach to Problem-Solving

38. 8D Approach to Problem-Solving
Cross Functional Team
(CFT)
- made up of members
from many disciplines.
Quality-One takes this
principle one step further
by having two levels of
CFT:
D1 Use a Team Approach Team selection and makeup
Core Team
- uses data-driven
approaches (Inductive or
Convergent Techniques)
The Core Team Structure
should involve three
people on the respective
subjects: product, process
and data

39. 8D Approach to Problem-Solving
SME Team
- members who brainstorm,

study and observe (Deductive

or Divergent Techniques)
Additional Subject Matter
Experts are brought in at
various times to assist with
brainstorming, data collection
and analysis
Teams require proper
preparation and setting
the ground rules.
 Implement disciplines

like checklists,
 forms and techniques
to ensure steady
progress.
 
Team selection and makeup

40. 8D Approach to Problem-Solving
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)
Team selection and makeup
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

41. 8D Approach to Problem-Solving
D2 Describe the Problem
The importance of collecting & interpreting data
 Problem statements and operational
definitions
 Flow charts
 Exercise: 
Use an IS/IS NOT worksheet to develop problem
definition

42. 8D Approach to Problem-Solving
D2 Describe the Problem
8D method’s focus is to properly describe the
problem,
utilizing the known data &
placing it into specific
categories for future
comparisons.

43. 8D Approach to Problem-Solving

44. 8D Approach to Problem-Solving
D2 Describe the Problem
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.
8D
 FORMAT

45. 8D Approach to Problem-Solving
D2 Describe the Problem
This approach utilizes the following tools:
 5 Why 
or Repeated Why
(Inductive tool)
Problem Statement
 Affinity Diagram (Deductive tool)
 Fishbone/Ishikawa Diagram
(Deductive tool)
 Is / Is Not (Inductive tool)
Problem Description
8D
 FORMAT

46. 8D Approach to Problem-Solving
D2 Describe the Problem
 Exercise: 
Use an IS/IS NOT worksheet to develop problem
definition8D
 FORMAT

47. 8D Approach to Problem-Solving
D3 Implement and Verify Containment Activity
Containment strategies -Thinking outside the box
Problems with containment
Exercise: 
Identify possible containment strategies
D3: Interim Containment Action
In the interim, before the
permanent corrective action
has been determined, an
action to protect the customer
can be taken.
8D
 FORMAT

48. 8D Approach to Problem-Solving
The Interim Containment Action (ICA) is temporary and
is typically removed after the Permanent Correct Action
(PCA) is taken.
D3 Implement and Verify Containment Activity
Verification of effectiveness
of the ICA is always
recommended to prevent
any additional customer
dissatisfaction calls
8D
 FORMAT

49. 8D Approach to Problem-Solving

50. 8D Approach to Problem-Solving
D4 Define Root Cause
 Root cause analysis methodology
 Structured brainstorming techniques
 Cause and Effect (Fishbone) Diagrams
 Repeated Whys (5 Whys)
 Cause of Occurrence vs. Cause of Escape
Exercise: Use structured brainstorming methods, and
a
 fishbone diagram to identify and classify possible root causes.
Exercise: Design a simple experiment to isolate root cause
 Run Charts
 

Exercise: Construct a run chart
   

51. 8D Approach to Problem-Solving
Cause and Effect (Fishbone) or (Ishikawa) Diagrams
It
 look like a 
fish's
skeleton 
with the
problem at its head
and the causes for the
problem feeding into
the spine.
-helps to track down the reasons for imperfections,
variations, defects, or failures.

52. 8D Approach to Problem-Solving
Cause and Effect (Fishbone) or (Ishikawa) Diagrams

53. 8D Approach to Problem-Solving
D4 Define Root Cause
Root Cause Analysis (RCA) and Escape Point.
Analyze & identify root cause to take permanent
action to eliminate it.
The root cause definition
requires that it can be turned
on or off, at will.
Activities include:
Comparative Analysis listing
differences and changes
between “Is” and “Is Not”
8D
 FORMAT

54. 8D Approach to Problem-Solving
Activities of D4 Root Cause
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,
(closest point in process where the
root cause could have been found
but was not)

55. 8D Approach to Problem-Solving
Activities of D4 Root Cause
The steps and techniques of RCA within 8D are as follows:
Problem Symptom
 is quantified &
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)

56. 8D Approach to Problem-Solving
Cause and Effect (Fishbone) or (Ishikawa) Diagrams

57. 8D Approach to Problem-Solving
Affinity Diagram
A business tool used to organize ideas and data and
grouped them based on their natural relationships
( 7 QC Tools ).
The Affinity process

is
often used to group
ideas
generated by
Brainstorming.

58. 8D Approach to Problem-Solving

59. 8D Approach to Problem-Solving
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

60. 8D Approach to Problem-Solving
Activities of D4 Root Cause
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) the Root Causes

61. 8D Approach to Problem-Solving

62. 8D Approach to Problem-Solving
Exercise:
Use structured brainstorming methods,
and
 fishbone diagram to identify and classify
possible root causes
Exercise: Design a simple experiment to isolate
root cause
 

Run Charts
 

Exercise: Construct a run chart
   

63. 8D Approach to Problem-Solving
Run Charts
-line
 
graph 
of data plotted over time. By collecting and
charting data over time, you can find trends or patterns
in the process.
Exercise: Construct a run chart
   
Run Charts do not use
control limits thus it is unable
to tell if a process is stable.
However, they can show how
the process is
 
running.

64. 8D Approach to Problem-Solving
Run Charts

65. 8D Approach to Problem-Solving
Developing an Action Plan
Error Proofing (Poka Yoke)
Nominal Group Technique (NGT)
 Exercise: 
Use NGT to reach consensus on corrective
actions - develop PCAs 
D5 Develop Permanent Corrective Actions (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.

66. 8D Approach to Problem-Solving
The
 
nominal group technique 
(
NGT)
-a group process involving problem identification,
solution generation, and decision making.
 
Can be used in groups of many
sizes, to make own decision
quickly, taking everyone's
opinions into account.
(as opposed to traditional voting,
where only the largest group is
considered)

67. 8D Approach to Problem-Solving

68. Poka-Yoke:
A Japanese mistakes avoid (poka-yokeru) method to
eliminate product defects by preventing, correcting, or
drawing attention to human errors as they occur.
  
Applicable in Lean Companies
and now in all manufacturing to
eliminate defects and prevents or
makes it impossible for human to
make an error.
8D Approach to Problem-Solving

69. 8D Approach to Problem-Solving
Activities in D5 include:
Establish the Acceptance Criteria which include
Mandatory Requirements and Wants
D5 Develop Permanent Corrective Actions (PCA)
Perform a Risk
Assessment /
 
Failure
Mode and Effects
Analysis (FMEA)
 
on the
PCA choices
8D
 FORMAT

70. 8D Approach to Problem-Solving
 Select control-point
improvement for the
Escape Point
 Verification of Effectiveness

for both the PCA and the
Escape Point are required
D5 Develop Permanent Corrective Actions (PCA)
Based on risk assessment, make a balanced choice
for PCA

71. 8D Approach to Problem-Solving
Corrective Actions VS Preventive Actions

72. 8D Approach to Problem-Solving

73. 8D Approach to Problem-Solving
Exercise: 

Use NGT to reach consensus on
corrective actions
- develop PCAs
D5 Develop Permanent Corrective Actions (PCA)

74. 8D Approach to Problem-Solving
D6 Implement and Verify Corrective Actions
Putting the Action Plan into place
Action Matrix
Force Field Analysis
Histograms
 
Scatter diagrams
 Exercise: 
Use a scatter diagram   

75. 8D Approach to Problem-Solving
To successfully implement and Validate PCA for a
permanent change,
D6 Implement and Verify Corrective Actions
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

76. 8D Approach to Problem-Solving

77. 8D Approach to Problem-Solving
 Exercise: 
Use a scatter diagram (scatter plot,
 scatter graph
, or
correlation
 chart
) - a tool for analyzing relationships
between two variables for determining how closely the
two variables are related.
One variable is plotted
on the horizontal axis
and the other is plotted
on the vertical axis.

78. 8D Approach to Problem-Solving

79. 8D Approach to Problem-Solving
Identifying recurrence issues
Leveraging your success for maximum ROI
Value Stream Mapping (VSM)
Control Charts and Basics Concepts of SPC
Process Capability
D7
 Prevent Recurrence

80. 8D Approach to Problem-Solving
D7 affords the opportunity to preserve and share the
knowledge, preventing problems on similar products,
processes, locations or families.
D7
 Prevent Recurrence
Updating documents and
procedures / work
instructions are expected
at this step to improve
future use.

81. 8D Approach to Problem-Solving
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
D7
 Prevent Recurrence

82. 8D Approach to Problem-Solving

83. 8D Approach to Problem-Solving
8D Auditing
 Summary and Wrap-up
D8
 Congratulate Your Team
 
 
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.

84. 8D Approach to Problem-Solving

8D Auditing,
 Summary and Wrap-up
D8
 Congratulate Your Team
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.

85. 8D Approach to Problem-Solving
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
D8
 Congratulate Your Team
 
 

86. 8D Approach to Problem-Solving

87. THE PENCIL PARABLETHE PENCIL PARABLE
Take 5!Take 5!
Relax &
Watch!

88. ATTITUDE IS ATTITUDE IS
EVERYTHINGEVERYTHING
Take 5!Take 5!
Relax &
Watch!

89. A happy or satisfied customer often
doesn’t say a thing, or just tell a
few friends, but an unhappy or
dissatisfied customer tells a lot of
people to warn them.
“A happy customer tells a friend; an unhappy
customer tells the world”
The exact words and number of people told vary, but that
became popular in the mid-1980s, when the American
Management Association conducted a business study.
8D Approach to Problem-Solving

90. Customer satisfaction is the driving force for an
organization to improve its performance to both
Customers: external (clients, government regulatory
bodies, the public) and internal (employees, different
departments)
  Both external and internal
Customers have needs.
Quality stresses the
importance of satisfying
those needs.
8D Approach to Problem-Solving