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AESQRM000202103
SAE Industry Technologies Consortia provides that: “This AESQ Reference Manual is published by the AESQ Strategy
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voluntary and its suitability for any particular use is the sole responsibility of the user.”
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Aerospace Engine Supplier Quality (AESQ) Strategy
Group
The origins of the AESQ can be traced back to 2012. The Aerospace Industry was, and still is, facing many
challenges, including:
The Aero Engine manufacturers Rolls-Royce, Pratt & Whitney, GE Aviation and Snecma (now Safran Aircraft
Engines) began a collaboration project with the aim of driving rapid change throughout the aerospace engine
supply chain, improving supply chain performance to meet the challenges faced by the industry and the need
to improve the Quality Performance of the supply chain.
Suppliers to these Engine Manufacturers wanted to see greater harmonisation of requirements between the
companies. Each Engine Manufacturer had Supplier Requirements that were similar in intent but quite different
in terms of language and detail.
This collaboration was formalized as the SAE G-22 Aerospace Engine Supplier Quality (AESQ) Standards
Committee formed under SAE International in 2013 to develop, specify, maintain and promote quality standards
specific to the aerospace engine supply chain. The Engine Manufacturers were joined by six major Aero Engine
suppliers including GKN, Honeywell, Howmet Aerospace, IHI, MTU and PCC Structurals. This collaboration
would harmonise the aerospace engine OEM supplier requirements while also raising the bar for quality
performance.
Subsequently, the Aerospace Engine Supplier Quality (AESQ) Strategy Group, a program of the SAE Industry
Technologies Consortia (ITC), was formed in 2015 to pursue activities beyond standards writing including
training, deployment, supply chain communication and value-add programs, products and services impacting
the aerospace engine supply chain.
AESQ Vision
To establish and maintain a common set of Quality Requirements
that enable the
Global Aero Engine Supply Chain
to be
truly competitive through lean, capable processes
and a
culture of Continuous Improvement.
i
The SAE G-22 AESQ Standards Committee published six standards between 2013 and 2019:
In 2021 the AESQ replaced these standards, except for AS13001, with a single standard, AS13100.
The AESQ continue to look for further opportunities to improve quality and create standards that will add value
throughout the supply chain.
Suppliers to the Aero Engine Manufacturers can get involved through the regional supplier forums held each
year or via the AESQ website http://aesq.saeitc.org/.
ii
AESQ Reference Manuals
AESQ Reference Manuals can be found on the AESQ website at the following link:
https://aesq.sae-itc.com/content/aesq-documents
AESQ publishes several associated documents through the SAE G-22 AESQ Standards Committee supporting
deployment of AS13100. Their relationship with APQP and PPAP is shown in Figure 1.
Figure 1: AESQ Standards and Guidance Documents and the link to AS9145 APQP / PPAP
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RM13000 - 8D Problem Solving Method
Table of Contents
1. INTRODUCTION TO PROBLEM-SOLVING ............................................................................................................... 4
5. FORMS OF 8D ..................................................................................................................................................... 17
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RM13000 - 8D Problem Solving Method
D4 – Root Cause Analysis – What are the causes of the problem? ............................................................................ 27
D5 – Identify Permanent Corrective Actions(s) – For the immediate problem ........................................................... 29
D6 – Implement Permanent Corrective Actions(s) – Validate and check for effectiveness ........................................ 29
D7 – Implement Preventive Action(s) – Prevent recurrence ....................................................................................... 30
D8 – Congratulate the Team – Provide recognition ................................................................................................... 30
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RM13000 - 8D Problem Solving Method
LIST OF FIGURES
FIGURE 1: AESQ STANDARDS AND GUIDANCE DOCUMENTS AND THE LINK TO AS9145 APQP / PPAP .................................................... III
FIGURE 2: STRUCTURED PROBLEM-SOLVING DECISION TREE................................................................................................................ 5
FIGURE 3: PARETO PRINCIPLE ...................................................................................................................................................... 6
FIGURE 4: PROBLEM-SOLVING INTERRELATIONSHIP DIAGRAM ............................................................................................................ 8
FIGURE 5: PROBLEM-SOLVING METHODOLOGY ROADMAP .............................................................................................................. 10
FIGURE 6: EXCEL A3 8D FORM .................................................................................................................................................. 18
FIGURE 7: POWERPOINT 8D FORMAT (PAGE 1) ............................................................................................................................ 19
FIGURE 8: POWERPOINT 8D FORMAT (PAGE 2) ............................................................................................................................ 19
FIGURE 9: WORD 8D FORM (PAGE 1) ......................................................................................................................................... 20
FIGURE 10: WORD 8D FORM (PAGE 2) ....................................................................................................................................... 21
FIGURE 11: WORD 8D FORM (PAGE 3) ....................................................................................................................................... 22
FIGURE 12: CASE STUDY 1 USING EXCEL A3 8D FORM ................................................................................................................... 23
FIGURE 13: CASE STUDY 1 USING POWERPOINT 8D FORM (PAGE 1)................................................................................................. 25
FIGURE 14: CASE STUDY 1 USING POWERPOINT 8D FORM (PAGE 2)................................................................................................. 25
FIGURE 15: CASE STUDY 3 – HOW THE SHAFT LENGTH (X) CALCULATED ............................................................................................ 27
FIGURE 16: CASE STUDY 3 FISHBONE DIAGRAM ............................................................................................................................ 27
FIGURE 17: CASE STUDY 3 5-WHY DIAGRAM FOR DIRECT CAUSE EXAMPLE ........................................................................................ 28
FIGURE 18: 8D CASE STUDY 5 WHY DETECTION EXAMPLE .............................................................................................................. 28
FIGURE 19: 8D CASE STUDY – MARKING CHECK SHEET .................................................................................................................. 29
FIGURE 20: AESQ 8D INTERACTIVE TOOL CONTROL PANEL ............................................................................................................ 31
LIST OF TABLES
TABLE 1: TYPICAL CUSTOMER PROBLEM-SOLVING MILESTONE REQUIREMENTS ....................................................................................... 7
TABLE 2: AESQ 8D VS ARP9136 ................................................................................................................................................ 9
TABLE 3: 8D CASE STUDY CORRECTIVE ACTION SUMMARY .............................................................................................................. 30
TABLE 4: TOOL TRAINING FOR EACH DISCIPLINE ............................................................................................................................ 42
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RM13000 - 8D Problem Solving Method
1. INTRODUCTION TO PROBLEM-SOLVING
This Reference Manual has been created to support the requirements of AS13100 Section 10 and
provides information on the use of problem-solving methodologies to satisfy the requirements of this
standard.
A problem can be defined as;
“A perceived gap between the existing state and a desired state, or a deviation from a norm,
standard, or status quo”
Business Dictionary
In this definition the ‘problem’ can represent an improvement opportunity when addressing the gap
between the ‘existing state and the desired state’ or an issue when addressing a ‘deviation from a
norm or standard’.
ISO 9001, AS9100 and AS13100 require organizations to have a process to manage both types of
problems in Section 10 of their respective standards. ISO 9001 provides examples for improvement
that include;
• Corrective action
• Continual improvement
• Breakthrough change
• Innovation, and
• Re-organization
This Reference Manual will primarily focus on managing problems associated with products and
manufacturing processes, although some may also be applied to other situations such as service
issues and improvement.
AS13100 requires organizations to use the 8D methodology for customer escapes as described in
Chapter 6. Alternative approaches that meet the intent of this requirement may be used if approved
by the customer.
The other material in this Reference Manual is provided as guidance for managing other types of
problem-solving with varying degrees of complexity.
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RM13000 - 8D Problem Solving Method
2. PROBLEM-SOLVING APPROACHES
In every part of the business, there are issues that need to be managed.
However, not all issues will require an individual problem-solving investigation to be completed.
There are two main approaches to how problems can be managed;
1) Individual Root Cause Analysis & Corrective Action
2) Themed improvement
The following guidance aims to help clarify which approach should be selected.
Figure 2 illustrates the logic to consider when a new issue arises in deciding whether individual root
cause or themed improvement is most suitable.
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RM13000 - 8D Problem Solving Method
Pareto of Themes
35
30
25
% of all issues 20
15
10
5
0
Theme 1 Theme 2 Theme 3 Theme 4 Theme 5
Themes
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RM13000 - 8D Problem Solving Method
The organization should monitor the status of all problem-solving activity with the business to
ensure that the process is effective and timely.
Learning from investigations and improvement actions should be read across to areas that can
benefit from the insights gained. Wherever possible the organization’s Management System
processes should be updated along with the following documents, as applicable;
• Design FMEA
• Process FMEA
• Control Plans
• Work Instructions
• Audit Checklists
Records of the investigation and actions taken are required to be maintained by ISO9001 and
AS9100 (10.2.2).
Define Problem
Close
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RM13000 - 8D Problem Solving Method
3. PROBLEM-SOLVING METHODOLOGIES
Many types of Problem-Solving methodologies have been established. They range from the very
simple “Just Do It”, to the comprehensive Eight Discipline (8D) investigation approach, to the
broader DMAIC method.
The 8D approach is used to document external Customer escape issues or internal high pain defect
issues, to very simple “find and fix” methods that deal with problems that are more local and not in
need of an extensive investigation. All methods have their origination from the “Plan, Do, Check,
Act” approach developed by Walter Shewhart and W. Edwards Deming back in the 1920’s. The
figure below shows some of the breadth of problem-solving methods that have evolved overtime
and how they overlap.
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RM13000 - 8D Problem Solving Method
Whatever methodology is used the basic intent of any problem-solving process is to;
1. Define the problem and containment actions
2. Understand the root cause
3. List and assign actions to fix problem
4. Evaluate results and standardise if problem is solved
Many of the tools in used in these methods overlap, as such there is a section on the common
problem-solving tools. These tools may be found in Section 7.
The table below shows the equivalency between the AESQ Eight Disciples (8D) per RM13000 and IAQG Nine
Steps (9S) per ARP9136. Companies may use either method.
D5 - Determine Permanent Corrective Action(s) S5 - Define and Select Permanent Corrective Action(s)
S6 - Implement Permanent Corrective Action and
D6 - Implement Permanent Corrective Action(s) Check Effectiveness
S7 - Standardize and Transfer the Knowledge Across
D7 - Determine Preventative Action(s) Business
D8 - Recognize the Team and Close Out
Investigation S8 - Recognize and Close the Team
There is no significant difference between AESQ 8D per RM13000 and IAQG 9S per ARP9136. As such,
suppliers can use either method.
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RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
The 8D problem-solving process was established in the automotive industry in the early 1980s by
Ford Motor Company to standardize and improve the capability of problem-solving in their supply
chain. It was launched under the full title of Team Oriented Problem-Solving (TOPS) using the Eight
Disciplines (8D).
This methodology was to be used as a standard tool for Ford suppliers where;
• The problem cause was not known
• It was suspected that the problem was complex with potentially several contributory causes
• A cross functional team approach was required due to the complex nature of the problem being
investigated
This method has now been well established and has become the default problem-solving process in
many industries, including aerospace. It is well supported globally with training providers and
consultants experienced in it use.
The AESQ adopted this approach in 2015 as the harmonized methodology for key problem-solving
investigations. Typically, it is required for all customer escapes although each customer may invoke
it differently.
This chapter describes the expectations for meeting the requirements of AS13100 when 8D is
required. When required the organization uses one of the 8D form as described in this chapter and
available from the AESQ Website. The purpose of this form is not to restrict the investigation
approach but instead is designed to provide;
• A standard method of reporting the summary of the investigation to the customer. This is
particularly useful where an organization may have hundreds of suppliers who are required to
submit investigation reports.
• Creates a common language for problem investigation reporting.
• Useful list of key questions to ask and evidence to gather at each stage of the investigation.
This will help to improve the rigor of the investigation. These prompts are based on learning
from experience from reviewing thousands of investigations by the AESQ member companies.
• Provide a record (evidence) of the investigation for future reference
The correct training of 8D practitioners is key to the successful outcome of the process. It is
expected that 8D practitioners are trained by a training provider meeting the requirement of the
“training syllabus” (see Appendix B). One of the roles of the 8D practitioner is to ensure that the 8D
Report is complete.
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RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
D5 Identify Permanent Corrective Action for Root Cause and Escape Point
The organization identifies the corrective actions that permanently eliminate the generation and
escape root causes.
D5 is completed in a timely manner not to exceed 30 days of the problem being identified unless
otherwise agreed with the customer.
Actions:
• Identify permanent corrective actions for all root causes identified.
• Verify that the corrective actions are effective and do not cause further problems.
• Define the actions required to fix the control system at the escape point so no further
occurrences are created.
D7 Prevent Recurrence
The organization takes appropriate systemic action (modify policies, procedures, practices,
standard work, design manuals, etc.) to prevent recurrence of this problem and other similar
problems and capture the lessons learned.
NOTE: The team may not have the authority to implement systemic actions, in this case they make
recommendations to the Champion for implementation.
The champion ensures that recommendations are appropriate to the scale of problem and have
responsibility for implementation.
Actions:
• Identify further affected parties, products, processes, or systems for similar problems and read-
across opportunities for improvement(s).
• Implement read-across actions to prevent further problems.
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RM13000 - 8D Problem Solving Method
4D Methodology
The 4D approach draws from the steps of 8D per Figure 5. The steps are:
• D2 (Define Problem),
• D4 (Determine Root Causes),
• D5 (Determine Permanent Corrective Actions) and
• D6 (Implement and Validate Corrective Actions).
Each of these four steps were previously described above.
Use these questions below to determine if the full 8D is required or of a shorter version would be
appropriate Use the following set of questions to aid in that decision:
1) Did this problem result in a product escape?
2) Does this problem require an emergency containment action?
3) Does this problem require population bounding?
4) Does this problem require a set of interim containment actions?
If the answer is “yes” to two or more of the four questions above, it is best to utilize the entire nine
steps of the 8D investigation process. Otherwise, start with the 4D shortened version, expand if
needed as more information becomes available. Examples of when a 4D is appropriate could be a
problem contained to a specific factory cell, such as a machine breakdown, part non-conformance
or yield issue where no defective units left the station.
Note that no two problems are alike. A problem might start using the 4D approach and through the
process the team or team leader might realize that a temporary (interim) action is needed, in this
case step D3 is added and a 5D investigation. This is very appropriate to do.
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RM13000 - 8D Problem Solving Method
solver instinctively reaches for a new set of batteries and replaces the ones in the flashlight, pushes
the switch, the light goes on. The 2D approach draws from the steps of 4D per Figure 5 with the
steps being D2 (Define Problem) and D6 (Solve Problem). These two steps are previously
described above.
When should one recognize that they do not need to perform all the four steps of a 4D? Use the
following set of questions to aid in that decision:
1) Can the problem be resolved immediately without a lengthy investigation?
2) Is the root cause readily understood?
3) Is the solution readily available to implement?
4) Are containment actions not likely to be needed?
If the answer is “yes” to the question set above, go ahead and implement a 2D type investigation.
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RM13000 - 8D Problem Solving Method
5. FORMS OF 8D
There are three different forms provided here in this section meet the requirements but are not
required to be used if a form is already in use that meets the 8D requirements. Customers may
require a specific form of the report.
A3 Excel 8D Methodology
This follows the same steps as for an 8D, but it is less prescriptive, and this allows it to be a useful
tool for non-product related issues. In a work environment, it is good practice to print the A3 sheet
and post onto team boards to increase visibility of current investigation(s) and drive active
engagement in the problem-solving process.
Based on the prior discussion of 8D, the following incorporates additional 8D guidance when using
the A3 format. Figure 6 shows a blank A3 form. Follow steps D1 – D4, D5/D6 and D7/D8 are
combine.
D1. Form the Team – Pull together as many people that are familiar with the problem as possible.
Process Users are particularly important as they understand the detailed steps and issues that
occur. Ensure Subject Matter Experts (SMEs) are drawn into the team.
D2. Define the Problem – Once the team is formed, define the problem - once again stick to the
facts of what actually happened and don’t make assumptions. If necessary, walk the process with
the team to really see what is happening. The 5W2H or SMARTI tool in Section 7.
D3. Implement Containment – Once the problem is fully defined and understood by the team
determine what the containment activity is to prevent the problem recurring whilst the root cause is
investigated.
D4. Find the Root Cause – Recommend using tools from Section 5 to determine the root cause of
the problem.
D6. Fix the Root Cause – Once the team has determined the root cause of the problem using the
most appropriate methodology, then the solution(s) to the problem should make itself clear to the
team and it should be implemented. It is important not to walk away from the problem at this stage
but ensure that the actions have owners and they have the support necessary to implement the
corrective action. The corrective action should be reviewed to ensure that it is effective.
D7. and D8. Fix the System issues, Read Across and Recognize the Team – In this final step
the team need to think about ways of preventing the problem from happening again. Also, the team
should look at opportunities of reading fixes across similar processes, other locations / components
that may be affected by the same issue. When this work is complete, it is important to recognize the
good work that the team have completed in fixing the problems and communicate to the local
management the fix that has been implemented and the results.
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RM13000 - 8D Problem Solving Method
18
RM13000 - 8D Problem Solving Method
The second page starts with determining Root Cause through the 3x5 Why method (step D4) and
continues through step D7 preventative action. The steps follow the direction of the standard 8D,
just are presented differently.
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RM13000 - 8D Problem Solving Method
20
RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
6. CASE STUDIES OF 8D
The following three case studies are all real problems that were solved using the 8D methodology.
Each case is presented in a different format, all of which are acceptable. The common thread is the
9 steps of the 8D process.
Case Study 1 presents an example shows each step in the form. Case Study 2 provides some
background to the case and some summary thoughts on how the investigation was completed and
then presents the PowerPoint 8D Form. Case Study 3 walks through the teams thought process in
detail using each of the nine steps of the 8D methodology. Each root cause tool used is also
demonstrated in the case study in the appropriate step.
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RM13000 - 8D Problem Solving Method
Team (D1)
A team was created to investigate the issues relating to the non-conformance. This team was
comprised of members from ACME Supplier and its customer Turbines. Team member expertise
included customer quality engineer, supplier quality engineer, statistician, customer quality
manager, supplier quality manager.
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RM13000 - 8D Problem Solving Method
25
RM13000 - 8D Problem Solving Method
26
RM13000 - 8D Problem Solving Method
Figure 15: Case Study 3 – How the Shaft length (X) calculated
The team, per the problem definition, utilized a Problem Statement, Fishbone Diagram, and 5-Why
Analysis to identify the causal factors and subsequent root causes of the problem. These causes
are broken down into the categories of direct, detection and systemic.
First, the team determined the causal factors for the Problem Definition using the Fishbone Diagram
as seen below.
PROBLEM DEFINITION
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RM13000 - 8D Problem Solving Method
5-WHY DIAGRAM
8D
8D
What is happening that shouldn’t be at the process Generation Point?
(HINT: Do not was te the 1 s t “why ” by res tating the problem; what is the failure mode or abs enc e of the requirement?)
“On April 15, 2020, the Customer reported that the dimension marking on
the shaft provided by the Supplier – which is nominally 935.40 +/- 0.4mm ,
is outside of limits on 4 of the shafts: S/N’s 120, 121, 122 and 123.”
Why is this happening?
Theref ore
Operator marked incorrect (out-of-
1 tolerance) dimension on shaft
2
Caution: Your last answer should be a cause you can correct and control
Figure 17: Case Study 3 5-Why Diagram for Direct Cause Example
Note the use of the “Therefore” test as part of the 5-Why Analysis. The 5-Why Analysis must make
sense going from top-to-bottom asking “Why” and from bottom-to-top stating “Therefore”. This helps
to validate the 5-Why analysis.
Third, the team conducted a 5-Why Analysis for the detection cause of the problem. This is shown
in the diagram below.
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RM13000 - 8D Problem Solving Method
Drawing Revision
(図面のリビジョン)
年 月 日 OP-
(YYYY/MM/DD) (OP No.)
P / N S / N
9 3 5 . * * DBA L
The total length is within the range of 935.00 - 935.80.
(全長寸法は935.00 - 935.80 の範囲内であること。) Prepared Checked
(作成者) (再確認者)
Marking Check / Inspector
(マーキング確認 / 検査員)
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RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
The use of basic quality tools are strongly recommended as part of the problem resolution process
no matter what specific methodology is applied. Many problem-solving tool are available in the
Interactive 8D tool on AESQ (add link) and on https://asq.org/quality-resources/seven-basic-quality-
tools with instructions on how to use for problem-solving tools and templates to use.
The figure below shows AESQ 8D Interactive Tool Control Panel, each button is a hyperlink (when
downloaded from AESQ). The left-hand column of the panel are the four key actions: Immediate
(D0-D2), Interim (D3-D4), Permanent (D5-D6), and Preventative (D7-D8). The second column,
Process Steps and Key Words, has the step by step instructions to walk the user through the 8D
process. The third column is the Tools Matrices, all the possible tools and templates that would
support an 8D investigation are in this column. The fourth column, or right-hand column is the key
questions that should be answered during the 8D investigation. Additionally, in the center of the
control panel is links to all the 8D forms.
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RM13000 - 8D Problem Solving Method
The following checklist is designed to assist in assessing the quality of the 8D activity.
Review the following assessing questions during execution of each step and before proceeding to
the next step.
D0 assessing questions
Are emergency response actions necessary?
Emergency
Is a field action required as part of the emergency response? How was the emergency response
Response
action verified?
Action (ERA)
How was the emergency response action validated?
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RM13000 - 8D Problem Solving Method
D1 assessing questions
What have you done to make the room user-friendly?
Warm Up
When and where will the team meet?
What has been done to help team members build their relationships with each other?
What has been done to help team members focus on the team's activity?
Has the purpose of the meeting been stated?
Has the team been informed of the agenda for the meeting?
Product /Process What special skills or experience will the team require in order to function effectively?
Knowledge
Have the team's goals and membership roles been clarified?
Operating
Does the team have sufficient decision-making authority to accomplish its goals?
Procedures
How will the team’s information be communicated internally and externally?
and Working
Do all members agree with and understand the team's goals?
Relationships
Are team members’ roles and responsibilities clear?
Is a facilitator needed to coach the process and manage team consensus?
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Common
Do we have the right team composition to validate the current step and proceed to the next?
Tasks
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Have we reviewed all these assessing questions with the sub tier if the issue was caused by the
latter?
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RM13000 - 8D Problem Solving Method
D2 assessing questions
Can the Symptom be subdivided?
Symptom
Has a specific Problem Statement been defined (object and defect)?
Problem Statement
Have 'Repeated Whys' been used?
What's wrong with what?
Do we know for certain why this is occurring?
Has Is/Is-Not Analysis been performed (what, where, when, how big)?
Problem Description
When has this problem appeared before?
Where in this process does this problem first appear?
What, if any, pattern(s) is (are) there to this problem?
Are similar components and/or parts showing the same problem?
Has the current process flow been identified? Does this process flow represent a change?
Have all required data been collected and analyzed?
How does the ERA affect the data?
Is there enough information to evaluate to identify potential root causes?
Do we have physical evidence of the problem?
Has a Cause & Effect Diagram been completed?
Does this problem describe a 'something changed' or a 'never been there' situation?
Type of Problem
Has the Problem Description been reviewed for completeness with customer and affected
Review of Problem
parties?
Description
Should this problem be reviewed with executive management?
Should financial reserves be set aside?
Should any moral, social or legal obligations related to this problem be considered?
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Common
Do we have the right team composition to validate the current step and proceed to the
Tasks
next?
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Have we reviewed all these assessing questions with the sub tier if the issue was caused
by the latter?
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RM13000 - 8D Problem Solving Method
Have the appropriate departments been involved in the planning of this decision?
Planning
Are the appropriate Advanced Product Quality Planning (APQP) tools available (e.g.,
FMEA, control plans, instructions)?
Have plans, including action steps, been identified (who needs to do what by when)?
Has a validation method been determined?
Does the customer have a concern with this ICA (is customer’s approval required)?
Have we identified what could go wrong with our plan and have preventive and
contingency actions been considered?
Are implementation resources adequate?
Does the validation data indicate that the customer is being protected?
Post Implementation
Can the ICA effectiveness be improved?
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Common Tasks
Do we have the right team composition to validate the current step and proceed to the
next?
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Has timely on-site support been deployed as needed?
Have we reviewed all these assessing questions with the sub tier if the issue was caused
by the latter?
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RM13000 - 8D Problem Solving Method
D4 assessing questions
Has the factual information in the Problem Description been updated? Is it consistent with
General
the previously performed is/is not analysis?
What sources of information have been used to develop the potential root-cause list?
Is there a root cause (a single verified reason that accounts for the problem)?
Root Cause
What factor(s) changed to create this problem? What data is available that indicates any
problem in the manufacturing or design process?
How did we verify this root cause?
Does this root cause explain all the facts compiled at D2?
Does the root cause analysis address the system level issue?
Have appropriate Advanced Product Quality Planning (APQP) tools been considered?
Potential Root Cause
(e.g., FMEA, control plans, instructions)
Is there more than one potential root cause?
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)?
How did you determine assignment of percent contribution?
If the level is achievable, has the team considered and reviewed with the Champion the
benefit of developing a separate problem description (and, by definition, separate 8D) for
the one or more contributing potential root cause(s)?
If the level is not achievable, has the team considered and reviewed with the Champion the
benefit of alternate problem-solving methods?
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Common Tasks
Do we have the right team composition to validate the current step and proceed to the
next?
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Have we reviewed all these assessing questions with the sub tier if the issue was caused
by the latter?
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RM13000 - 8D Problem Solving Method
What criteria have been established for choosing a PCA for the root cause and escape
point?
Does the Champion agree with these criteria?
Is a field action required as part of the PCA?
What choices have been considered for the PCA's?
Document the rationale for the validation analysis
What features and benefits would the perfect choice offer? How can we preserve these
benefits?
What risks are associated with this decision and how should they be managed?
Does the Champion concur with the PCA selections?
What evidence (proof) do we have that this will resolve the problem at the root-cause level?
Did you verify the whole variation range of parameters affecting the cause occurrence?
Which variables did we measure during the verification step? Do these indicators constitute
sound verification?
What are the possibilities that this choice, once implemented, will create other troubles?
Can the customer live with this resolution?
Will our containment continue to be effective until our choice can be implemented?
What resources will be required for PCA implementation? Do we have these resources?
What departments will need to be involved in the planning and implementation of this
decision?
Have actions been considered that will improve the ICA prior to PCA implementation?
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Do we have the right team composition to validate the current step and proceed to the next?
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Have we reviewed all these assessing questions with the sub tier if the issue was caused by
the latter?
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RM13000 - 8D Problem Solving Method
D6 assessing questions
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Do we have the right team composition to validate the current step and proceed to the
next?
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Have we reviewed all these assessing questions with the sub tier if the issue was caused
by the latter?
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RM13000 - 8D Problem Solving Method
D7 assessing questions
What policies, methods, procedures and/or systems allowed this problem to occur and escape?
Prevent Actions
What needs to be done differently to prevent recurrence of the root cause? Of the escape point?
(this problem and
Is a field action required as part of the prevention actions?
similar problems)
What evidence exists that indicates the need for a process improvement approach
Who is best able to design improvements in any of the systems, policies, methods and/or
procedures that resulted in this root cause and escape?
What is the best way to perform a trial run with these improvements?
What plans have been written to coordinate Preventive Actions and standardize the practices?
Does the Champion concur with the identified Prevent Actions and plans?
How will these new practices be communicated to those affected by the change?
Have we standardized all the practices that need standardization?
What progress check points have been defined to assess system improvements?
What management policy, system or procedure allowed this problem to occur or escape?
Systemic Prevent
Are these practices beyond the scope of the current Champion?
Recommendations
Who has responsibility for these practices?
Does the current Champion agree with the team's systemic prevention recommendations?
Have all changes been documented (e.g., FMEA, control plan, process flow)?
Common Tasks
Have all systems, practices, procedures, documents, etc. been updated? Do they
accurately reflect what we want to be done from here?
Do we have the right team composition to validate the current step and proceed to the next?
Have we reviewed the measurable(s)?
Have we determined if a field action is required?
Have we reviewed all these assessing questions with the sub tier if the issue was caused by the
latter?
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RM13000 - 8D Problem Solving Method
D8 Assessing Questions
What have you learned as individuals and as a team? About yourselves? About problem-solving?
About teamwork?
How did the organization benefit by the completion of this 8D process?
Review each 8D objective. What was done well?
What sort of things should be repeated if conditions bring them together again on another 8D?
Are there changes to the business practices that should be considered, based on the learning in
this 8D?
Have we reviewed all these assessing questions with the sub tier if the issue was caused by the
latter?
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RM13000 - 8D Problem Solving Method
The purpose of this syllabus is to define the minimum requirements that an 8D training course should cover to
meet customer expectations.
The training provider should check that the trainees have baseline understanding of:
Competencies of the trainees should be assessed with a written exam covering the content of the syllabus.
The training should review and explain the 8D process and customer requirement (see §1).
The training should review and explain the Problem-Solving Form (see ).
The training provider should plan specific tool training regarding each step of the 8D depending on customer
requirements.
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RM13000 - 8D Problem Solving Method
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RM13000 - 8D Problem Solving Method
ESCAPE POINT: The earliest point in the process where the problem should have been detected.
FAILURE MODE: The manner in which a component, subsystem, system, or
manufacturing/assembly process could potentially fail to meet or deliver its intended function(s) or
process requirements.
GENERATION POINT: The point in the process where the failure mode was created.
INTERIM CONTAINMENT ACTION (ICA): Immediate temporary actions taken in order to eliminate
or significantly reduce the effect of the Failure Mode on the customer(s) until permanent corrective
actions are in place and verified.
PERMANENT CORRECTIVE ACTION (PCA): Long-term actions taken to address the problem from
its root cause(s) and fix it permanently.
PROBLEM: Description of an issue where a product does not meet the required standard.
RECURRENCE: Subsequent nonconformance with the same underlying Root Cause.
ROOT CAUSE: The fundamental deficiency or failure of a process that when resolved, prevents or
significantly reduces the likelihood of recurrence of the problem.
SYMPTOM/FAILURE MODE EFFECT: Measurable events or effects that indicate the existence of
one or more problems.
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RM13000 - 8D Problem Solving Method
This reference manual represents the consensus of the members of the AESQ. The Team
members who developed this guidance and whose names appear below, wish to acknowledge the
many contributions made by individuals from their respective organizations.
Organization Representative
Rolls-Royce Ian Riggs – Team Co-Leader
IHI Jun Sakai
Pratt & Whitney Pete Teti
Pratt & Whitney Peter Papadopoulos
Rolls-Royce Ricardo Banuelas
MTU Tobias Kranz
Honeywell Adam Rogers
GE Marnie Ham
Rolls-Royce Karl Evans
GKN Aerospace Roger Persson
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RM13000 - 8D Problem Solving Method
Change History
Revision Date Description of Change
March
Initial Release
2021
Email: info@aesq.sae-itc.org
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