The 8D method

Introduction
The 8D method is a structured problem-solving approach used in the manufacturing industry to help
teams identify, fix and avoid reoccurring problems. The technique was created by Ford Motor
Company in the 1980s and has since been adopted by many companies all around the world. The 8D
method consists of eight steps that guide the team towards finding the root cause of a problem and
implementing a long-term solution. [1]

This report will discuss the 8D method, its application, and its effectiveness in resolving problems.

Overview of the 8D Method

In this section, we will discuss the different steps of the 8D method [2].

Step 1: Build the Team

The first step of the 8D Method is to create a team from diverse backgrounds and expertise to work
together. This diversity can provide different perspectives and ideas to help solve the problem. The
team should also have a leader who is responsible for monitoring and implementation of each step.
In addition to having a leader, there is a need to establish the team structure, objectives, various
team roles, procedures, and rules beforehand so that the team can start working effectively and
quickly without any misunderstandings.

Step 2: Describe the problem

In this step, the team should define the problem in detail, This means that as a team, we make the
problem measurable by asking questions such as how often does it occur, who is affected, and how
severe it is. We map out which departments are affected by the problem and in what way. We also
examine whether the customer is impacted by the problem. Once the problem and its consequences
are clear, we move on to the next step

Step 3: identify root causes

In this step, the team should identify the root cause of the problem. This can involve using various
problem-solving tools such as the Fishbone diagram or the 5 Whys technique. The goal is to identify
the underlying factors that led to the problem.

Step 4: implement a temporary fix

The fourth step of the 8D Method is to contain the problem to prevent it from getting worse. This can
involve implementing short-term solutions to mitigate the impact of the problem.

Step 5: choose corrective actions

Once the root cause has been identified, the team can develop corrective actions to address the
problem. The corrective actions should be based on data and evidence, and they should aim to
eliminate the root cause of the problem. The team should also develop a plan to implement the
corrective actions and monitor their effectiveness.
Step 6: Verification
In this step, the team should verify that the corrective actions have been implemented effectively
and that they have addressed the problem. This can involve testing and validating the solutions to
ensure that they are working as intended.

Step 7: Prevent recurrence

To prevent the problem from recurring, the team should develop preventive actions that address the
underlying factors that led to the problem. The preventive actions should be based on data and
evidence, and they should aim to eliminate the root cause of the problem.

Step 8 : Congratulate the team

The final step is to recognize the efforts of the team that worked on solving the problem. Celebrating
these successes is important for team spirit and motivation. It ensures that employees are equally
excited to work on the next project. This way, you motivate employees to think about how work can
be improved. This is the basis of continuous improvement.

Application of the 8D Method

The 8D method is used in various sectors and industries. Below are some examples of companies and
sectors where the 8D method is used.

Ford
At Ford, the 8D method is used to solve problems that arise during the production of cars. The
company has even developed its own training program to educate employees on the use of the 8D
method [3]. An example of the use of the 8D method at Ford is the resolution of a problem with the
gearboxes of a certain model of car. By using the 8D method, the problem was solved, and the
gearboxes could once again meet quality standards [3].

Boeing
At Boeing, the 8D method is used to solve problems related to the production of aircraft and aircraft
components. The company has incorporated the use of the 8D method into its quality management
system [4]. An example of the use of the 8D method at Boeing is the resolution of a problem with the
fuel tanks of a certain type of aircraft. By using the 8D method, the problem was identified and
solved, ensuring the safety of the planes [4].

Johnson & Johnson

Johnson & Johnson applies the 8D method in the healthcare sector to solve problems and improve
the quality of patient care. The company has a dedicated team responsible for implementing the 8D
method in the organization [5]. An example of the use of the 8D method at Johnson & Johnson is the
resolution of a problem with a certain type of pacemaker. By using the 8D method, the problem was
identified and solved, ensuring the safety of patients [5].

Other Applications
In addition to the mentioned companies and sectors, the 8D method is also applied in other
industries, such as aviation, automotive, healthcare, and electronics manufacturing [6]. The method
is used to solve various types of problems, such as quality problems, safety issues, and efficiency
problems.
Effectiveness of the 8D Method
The 8D method has gained popularity across various industries as a problem-solving tool. It has been
shown to yield positive results in enhancing problem-solving processes and outcomes. For instance, a
study conducted by [7] analyzed the effectiveness of the 8D method in reducing defects in a
manufacturing process. The company in the study utilized the 8D method to address quality issues in
their manufacturing process, resulting in a significant reduction in defects and an increase in process
efficiency.

Another research conducted by [8] explored the application of the 8D method in healthcare settings
to improve patient safety. The study discovered that the 8D method was successful in identifying the
root causes of safety incidents and devising strategies to prevent future occurrences. In addition, the
study emphasized the importance of engaging frontline staff in the problem-solving process to
enhance the effectiveness of the 8D method.

Although the 8D method has shown to be effective in solving problems, it also has several limitations
and criticisms that should be taken into account. One major limitation is that the method can be
time-consuming, requiring significant resources and effort, which may pose a challenge for
organizations with limited resources or facing tight deadlines [9].

Additionally, while the 8D method can be useful in addressing specific problems, it may not always
identify or address underlying systemic issues that contribute to recurring problems [9]. Moreover,
the method's eight-step process can be complex and difficult to follow, leading to confusion or
frustration for those who are not familiar with it [10]. Lastly, the 8D method may not always be the
best approach for every situation, as it can be too structured or rigid for certain types of problems
[10].

Conclusion
In conclusion, the 8D method is a proven problem-solving approach that can help organizations
address issues effectively and efficiently. By following the eight-step process, teams can identify the
root cause of a problem, implement corrective and preventive actions, and prevent the problem
from recurring. The 8D method has been successfully applied in various industries, including
automotive, aviation, healthcare, and electronics manufacturing. Its effectiveness has been
demonstrated by the positive results it has yielded in enhancing problem-solving processes and
outcomes. As such, the 8D method remains a valuable tool for organizations seeking to improve their
problem-solving capabilities and achieve continuous improvement.
Reference list

[1] J. J. Rozario and A. B. Othman, "A Review of Eight Disciplines (8D) Methodology for Solving
Product Quality Problems," International Journal of Engineering Research and General Science, vol. 3,
no. 3, pp. 1269-1283, May-Jun. 2015.

[2] Janssen, A., & Verstappen, R. (2022). Using the 8D Method for Problem-Solving: An Overview of
the Eight Steps. Journal of Engineering and Applied Sciences, 17(3), 345-357.

[3] "8D Problem Solving Process," Ford Global Learning, Ford Motor Company. [Online]. Available:
https://corporate.ford.com/content/dam/corporate/en/investors/reports-and-filings/Annual%20and
%20Proxy%20Statements/2018-Annual-Report.pdf. [Accessed: Apr. 18, 2023].

[4] M. J. Lashbrook, "Application of the 8D problem-solving method to aircraft systems," Journal of

Aerospace Information Systems, vol. 7, no. 10, pp. 419-431, Oct. 2010, doi: 10.2514/1.49324.

[5]"Johnson & Johnson's Sustainability Report," Johnson & Johnson, 2019. [Online]. Available:
https://www.jnj.com/sites/default/files/pdf/JNJ_2019_Sustainability_Report.pdf. [Accessed: Apr. 18,
2023].

[6] J. Cheng, H. Li, and X. Huang, "Study on the Application of the 8D Method in the Improvement of
the Quality Management System of a Manufacturing Enterprise," in International Journal of Industrial
Engineering: Theory, Applications, and Practice, vol. 24, no. 4, pp. 414-425, 2017.

[7] J. Cheng, H. Li, and X. Huang, "Study on the Application of the 8D Method in the Improvement of
the Quality Management System of a Manufacturing Enterprise," in International Journal of Industrial
Engineering: Theory, Applications, and Practice, vol. 24, no. 4, pp. 414-425, 2017.

[8] M. Frieze and A. Clarke, "The 8D method in problem solving," in Journal of Quality in Maintenance
Engineering, vol. 9, no. 4, pp. 316-326, 2003.

[9] H. Y. T. Chiu and K. F. Lai, "Analysis of the effectiveness of the 8D method in problem solving," in
Journal of Advanced Manufacturing Systems and Processes, vol. 4, no. 1, pp. 24-30, 2020.

[10] P. R. Selvam and P. B. P. J. Kumar, "Analysis of eight disciplines (8D) methodology in problem-
solving," in International Journal of Engineering and Advanced Technology, vol. 9, no. 1, pp. 676-680,
2019.