Introduction to 8D

 The Eight Disciplines of Problem

Solving (8D) is a problem solving
methodology designed to find the root
cause of a problem, devise a short-
term fix and implement a long-term
solution to prevent recurring problems.
 When it’s clear that your product is
defective or isn’t satisfying your
customers, an 8D is an excellent first step
to improving Quality and Reliability.
 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.
What is 8D

 The 8D problem solving process is a

detailed, team oriented approach to
solving critical problems in the
production process. The goals of this
method are to find the root cause of a
problem, develop containment actions
to protect customers and take
corrective action to prevent similar
problems in the future.
 The strength of the 8D process lies in
its structure, discipline and
methodology. 8D uses a composite
methodology, utilizing best practices
from various existing approaches.
 It is a problem solving method that
drives systemic change, improving an
entire process in order to avoid not
only the problem at hand but also
other issues that may stem from a
systemic failure.
Why Apply 8D

The 8D methodology is so popular in

part because it offers your engineering
team a consistent, easy-to-learn and
thorough approach to solving whatever
problems might arise at various stages
in your production process. When
properly applied, you can expect the
following benefits:
• Improved team oriented problem
solving skills rather than reliance on
the individual
• Increased familiarity with a structure
for problem solving
• Creation and expansion of a database
of past failures and lessons learned to
prevent problems in the future
• Better understanding of how to use
basic statistical tools required for
problem solving
• Improved effectiveness and efficiency
at problem solving
• A practical understanding of Root
Cause Analysis (RCA)
• Problem solving effort may be adopted
into the processes and methods of the
organization
• 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
When to Apply 8D

The 8D problem solving process is

typically required when:
• 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
How to Apply 8D
The 8D process alternates inductive
and deductive problem solving tools to
relentlessly move forward toward a
solution. The Quality-One approach
uses a core team of three individuals for
inductive activities with data driven tools
and then a larger Subject Matter Expert
(SME) group for the deductive activities
through brainstorming, data-gathering
and experimentation.
D0: Prepare and Plan for the 8D
Proper planning will always translate to
a better start. Thus, before 8D analysis
begins, it is always a good idea to ask
an expert first for their impressions.
After receiving feedback, the following
criterion should be applied prior to
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), which
protects the customer from further
exposure to the undesired symptoms
D1: Form a Team
A Cross Functional Team (CFT) is made
up of members from many disciplines.
Quality-One takes this principle one
step further by having two levels of CFT:
 A 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
 SME Team comprised of 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.
Setting the ground rules is paramount.
Implementation of disciplines like
checklists, forms and techniques will
ensure steady progress. 8D must
always have two key members: a
Leader and a Champion / 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)
• 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
D2: Describe the Problem
The 8D method’s initial focus is to
properly describe the problem utilizing
the known data and placing it into
specific categories for future
comparisons. 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. 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
D3: Interim Containment Action
In the interim, before the permanent
corrective action has been determined, an
action to protect the customer can be
taken. The Interim Containment Action
(ICA) is temporary and is typically
removed after the Permanent Correct
Action (PCA) is taken.
• Verification of effectiveness of the ICA is
always recommended to prevent any
additional customer dissatisfaction calls
D4: Root Cause Analysis (RCA)
and Escape Point
The root cause must be identified to
take permanent action to eliminate it.
The root cause definition requires that it
can be turned on or off, at will. Activities
in D4 include:
• Comparative Analysis listing
differences and changes between “Is”
and “Is Not”
• 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, which is the
closest point in the process where the
root cause could have been found but
was not
D5: Permanent Corrective Action
(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. Activities in
D5 include:
• Establish the Acceptance Criteria which
include Mandatory Requirements and
Wants
• Perform a Risk Assessment / Failure
Mode and Effects Analysis (FMEA) on
the PCA choices
• Based on risk assessment, make a
balanced choice for PCA
• Select control-point improvement for
the Escape Point
• Verification of Effectiveness for both
the PCA and the Escape Point are
required
D6: Implement and Validate the
Permanent Corrective Action
To successfully implement a permanent
change, proper planning is essential. 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
D7: Prevent Recurrence
D7 affords the opportunity to preserve
and share the knowledge, preventing
problems on similar products,
processes, locations or families.
Updating documents and procedures /
work instructions are expected at this
step to improve future use. 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
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. 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