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Eight Disciplines Problem Solving is a method used to approach and to resolve problems, typically employed by quality engineers or other

professionals. D0: The Planning Phase: Plan for solving the problem and determine the prerequisites. D1: Use a Team: Establish a team of people with product/process knowledge. D2: Define and describe the Problem: Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how and how many (5W2H) for the problem. D3: Developing Interim Containment Plan Implement and verify Interim Actions: Define and implement containment actions to isolate the problem from any customer. D4: Determine and Identify and Verify Root Causes and escape points: Identify all potential causes that could explain why the problem occurred. Also identify why the problem has not been noticed at the time it occurred. All causes shall be verified or proved, not determined by fuzzy brainstorming. D5: Choose and verify Permanent Corrective Actions (PCAs) for root cause and Escape point : Through pre-production programs quantitatively confirm that the selected corrective actions will resolve the problem for the customer. D6: Implement and validate PCAs: Define and Implement the best corrective actions. D7: Prevent recurrence: Modify the management systems, operation systems, practices and procedures to prevent recurrence of this and all similar problems. D8: Congratulate your Team: Recognize the collective efforts of the team. The team needs to be formally thanked by the organization.[1][2] 8D has become a standard in the Auto, Assembly and other industries that require a thorough structured problem solving process using a team approach. www.johnwoodruffe.co.uk

TO DETECT IT EARLIER CHECK . / which area on body / first no good/ tendency on other bodies etc ) APPROPRIATE STANDARD D2 SKETCH DETECTION PROCESS NAME MEASURE POINT OF DETECTION D3 QPS NUMBER ACTION CONTAINMENT SEQUENCE / BODY NUMBER (Date / Time) CHECK CONTAINMENT D4 ALWAYS CONFIRM STANDARDISED WORK ADHERENCE DIRECT CAUSE MAT MAN WHY EFFECT WHY WHY POSSIBLE CAUSES POSSIBLE CAUSES ANALYSE WHY EQUIP METHOD WHY INVESTIGATE MOST LIKELY OK NG REASON ROOT CAUSE 1. STANDARDISED WORK ADHERENCE DIRECT CAUSE = TO STOP THE CAUSE COUNTERMEASURE QPS CHANGES WHO WHEN CHECK D5 D6 IMPROVE .PROBLEM SOLVING 8D SUMMARY SHEET DATE AREA REPORTED REF: D0 D1 SKETCH RESPONSIBLE SUPERVISOR DEFINE DEFINE RESPONSIBLE GROUP CLARIFY THE PROBLEM ( How many / which body spec. 2. D7 SHARE / FURTHER COUNTERMEASURE REPEAT PREVENTION CONTROL TEAM D8 . SHIFTS AGREE PAPERWORK CHANGES OPERATORS RETRAINED .

02 AS ABOVE –SHEETS SIGNED ON REVERSE BY OPERATORS S MIN BRIEF 1. ADDITIONAL CHECK (+1 OPERATOR) INSPECTION STN II – FITTING ADDITIONAL FOAM PAD TO REPAIR (# 67184) 2.3.3.02 .3.Back Portion Close to lock RESPONSIBLE GROUP Door line Range # 67112 0 # 69998 +1 DAY * OK +2 DAY OK Bill Friday DOOR INNER SKETCH D2 CLARIFY THE PROBLEM ( How many / which body spec.4.3. Torque Setting lock Join Bar Touching Door Outer STANDARDISED WORK ADHERENCE OK NG OK 100 VEH CHECKED STRIP DOWN N/G VEHICLE REGULATOR BAR TOUCHING DOOR BEAM Worn Punch on Part #53811 (No Standard check prior to run) (No Maintenance Schedule in place) DIRECT CAUSE = TO STOP THE CAUSE COUNTERMEASURE QPS CHANGES WHO WHEN CHECK Punch Type H34 Added to 3 monthly maintenance Schedule TO DETECT IT EARLIER IMPROVE MAINT SHEET H34 UPDATED H34 /QPS/2 D5 D6 Is 28. INVESTIGATE DOOR LINE FIT PROCESS + REPORT ALWAYS CONFIRM STANDARDISED WORK ADHERENCE 67184 CHECK CONTAINMENT 24/3 25/3 27/3 01/4 04/4 D4 DIRECT CAUSE MAT REGULATOR BAR GLASS SPECIFICATION MAN NO FIT OF FOAM PAD NEW OPERATOR EFFECT WHY WHY Regulator bar touching door beam Bar is out of position Top fitting is loose Hole has burr – holding off fixing WHY RATTLE POSSIBLE CAUSES Trim WHY POSSIBLE CAUSES ANALYSE TORQUE SETTING NG LOCK BOLTS CONNECT BAR SEQUENCE LOCK FIT SEQUENCE EQUIP METHOD Press WHY Poor Punching from Press Shop Punch is worn INVESTIGATE MOST LIKELY OK NG REASON ROOT CAUSE 1.02 TH PT PS JB QV SB PF JT 28.3. 29/6 29/7 29/3 29/4 D7 SHIFTS AGREE REPEAT PREVENTION CONTROL SHARE / FURTHER COUNTERMEASURE JB 28.02 D8 TEAM AS PT JB .02 29/3 29/429/5 29/6 29/7 CHECK ADDED TO PANEL CHECKSHEET k34/QPS/2 CHECK FOR NO BURR –IDENTIFIED AS QUALITY KEY POINT PAPERWORK CHANGES OPERATORS RETRAINED Is 28.PROBLEM SOLVING 8D SUMMARY SHEET DATE REF: 4000/67118/2 D0 D1 23.3 29. 29/5 .3 CHECK ALL DIES FOR PUNCH TYPE K34 STUDY + CONSIDER ALL PM CHANGE TO 3 MONTH PT BY 10. 2.02 AREA REPORTED FCPA SKETCH RESPONSIBLE SUPERVISOR DEFINE DEFINE Rattle From lH Door Interior (Front Door) .02 PH 29. / which area on body / first no good/ tendency on other bodies etc ) APPROPRIATE STANDARD Door Closing Noise (N/G) 20 15 10 5 LHF VIS: 318 / 2 +3 DAY OK 14 NO AUDIBLE NOISE RHF LHF RHF 0 0 0 100 Vehicles Checked (John Smith ) LOCK MECHANISM 14X NG * 1st N/G Vehicle 67000 DETECTION PROCESS NAME BURR HOLDS OFF FIXING CONTACT CAUSES NOISE D3 MEASURE POINT OF DETECTION * NOISE DOOR LINE INSP STN II SHIPPING * 1ST DOOR SHUT DOOR SHELL (OK) INPSECTION PROCESS STN II QPS NUMBER (OK) (OK) N/G DL 23108 SEQUENCE / BODY NUMBER (Date / Time) ACTION CONTAINMENT 1.4.