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8D Problem Solving Approach

Operational Excellence
What is 8D?
Ford Motor Company started a
problem solving process known as
8D
which takes
8 Disciplines
and uses them to tackle engineering problems
8D METHOD:

CUSTOMER:
BIRMINGHAM STOPPER
CORRECTIVE ACTION REPORT
8D TEAM:

CAR RAISED BY:


8 Disciplines
PART NO: DATE:
DESCRIPTION: LOG NO:
DEFECT/FAULT DESCRIPTION: INTERNAL: 4
EXTERNAL: 4

IMMEDIATE CORRECTIVE/CONTAINMENT ACTION:


ACTION BY: DATE:
• A typical form
is used for
ROUTE CAUSE DEFINITION:
ACTION BY: DATE:

the 8D
PERMANENT CORRECTIVE ACTION:
ACTION BY: DATE:
approach to
problem
VERIFY PERMANENT CORRECTIVE ACTION:
ACTION BY: DATE:
solving
ACTION BY: DATE:
PREVENT RECURRENCE (DOCUMENT UPDATE):
F.M.E.A. REVIEWED (Y/N)
CONTROL PLAN REVIEWED (Y/N)
WORKS ORDER TEXT REVIEWED (Y/N)

ACTION BY: DATE:


COMMENTS: DISTRIBUTION:

QC19 ISSUE 4 DATED 06/11/02


8D Problem Solving

• By taking this approach we can continuously


improve quality by eliminating the causes of
problems and prevent their reoccurrence.
What are the 8 Disciplines?
1. Define the problem.
2. Build a team.
3. Containment action.
4. Determine the root cause.
5. Verify the root cause.
6. Corrective Action.
7. Prevention.
8. Congratulate the team.
D1. Define the Problem

• Do we know EXACTLY what the problem is?

• Have we seen the problem before?

• What evidence of the problem is available?


D2. Build a Team
• Once a problem has been
bought to our attention, a
team must be formed to
tackle the problem.

• Ideally, this will be a team of


people with a variety of skills
and knowledge related to the
problem.
D3. Containment Action

• What action can be taken immediately?


• Do we have stocks that need sorting?
• Are we still manufacturing parts with the
problem?
• Will the actions that we take cause other
problems?
D4. Determine the Root Cause

• Has the cause of the problem been


identified?

• Is there more than one cause?

• Did we refer to the F.M.E.A.?


D5. Verify the Root Cause

• Are we sure that the root cause has been


properly identified?
D6. Corrective Action

• Has everyone been notified of the actions


taken?

• Have we reviewed and updated the relevant


F.M.E.A.?

• Have any temporary short term fixes been


removed?
D7. Prevention

• Have we taken all actions to prevent


reoccurrences?

• Have we considered other similar products


or processes?
D8. Congratulate the Team
• Have we identified each individual team
members contribution to solving the
problem?

• Have we acknowledged and appreciated


the efforts involved?
8D
• We have now seen the 8D problem solving
method.

• You may be called upon to help solve a


problem.

• Understanding the 8D approach will help in


tackling future problems.