IMPROVING OUTPUT QUALITY-

8D PROBLEM SOLVING

Hermilinda Q. Sumagpao, MBA, LPT

College of Entrepreneurship

2022-2023
TOPIC

B. 8 D Problem Solving
• 8D Methodology defined
• Benefits of 8D
• 8D Process
LEARNING OUTCOME

 Identify factors that affects output quality.

Explain techniques used to ensure consistent quality.
Understand the benefits of establishing control points for quality
outputs.
WHY WE NEED TO ADOPT / REINFORCE THIS
METHODOLOGY?
• Lack of a structured approach.
• Lack of teamwork approach.
• We address effects and symptoms but often the root cause is not detected / eliminated.
• We need to stop fighter fighting.
• We need to stop solving problems using just our feelings (Trial-Error approach).
• We need a methodology that helps us to verify effectiveness of actions
 8 D’S, AN ANALYTICAL PROBLEM-SOLVING TOOL.
When we must use it is because our prevention system failed.
• 8D Methodology is a systematic-problem solving method
• It was made popular by “Ford Motor Company” in the automotive industry
• These are 8 disciplines or 8 steps that must identifying and eliminating problem in a product, process, or
service
• Primary use is to solve PROBLEMS not to address opportunities of improvement.
• Problem: A deviation from a standard.
• Special causes and Common Causes (SPC). 8D is a very helpful tool in finding the source of special causes of
variability.
INTUITIVE APPROACH TO PROBLEM SOLVING VS.
ANALYTICAL
8 DISCIPLINES.
1. Establish the team.
2.Describe the problem.
3. Develop interim containment action.
4.Define and verify the root cause and escape point
5. Choose and verify permanent corrective action.
6. Implement and validate permanent corrective action.
7. System prevention actions to prevent a recurrence
8. Recognize team contribution
 D1 ESTABLISH THE TEAM

Purpose of D1:
✔ Establish a small group of people with relevant knowledge

Key Activities of the Team in D1:

✔ Review priorities, scope and problem
✔ Identify how big team is needed
✔ Identify team member and establish team
✔ Nominate a team leader, project champion and facilitator
✔ Assign the roles and responsibilitites
D2 DESCRIBE THE PROBLEM

Purpose of D2:
✔ Describe the internal or external issue by identifying “what is wrong with that” and detailing the
problem in qualifiable terms so it is easy to take further actions
Key Activities in D2:
✔ Develop a problem statement and a flowchart of all operations step and identify critical operations
step with respect to the problem
✔ Establish a high-level project plan, including milestones, project goals and objectives
✔ the description should define the boundaries.
 D3 DEVELOP INTERIM CONTAINMENT ACTION.

Purpose of D3:
✔ define, verify and implement interim containment action to isolate the effects of the problem from any internal
and/or external customer until permanent corrective actions are implemented.
Key Activities in D3:
✔ define the interim containment action.
✔ Verify the effectiveness of the interim containment actions
✔ Select and implement interim containment action
✔ Validate the effectiveness of the implemented interim containment action with the customer
 D3 DEVELOP INTERIM CONTAINMENT ACTION.

The Containment action must be implemented

✔ customer finished goods
✔ At the customer’s line
▪ Customer Relation Management storage
▪ Supplier’s Finished Goods storage

✔ At the supplier line

▪ Supplier Relationship Management storage
▪ Sub-supplier’s sequence of operations
D4 IDENTIFY AND VERIFY ROOT CAUSE AND ESCAPE POINTS

Purpose of D4:
✔ Root cause is identifiable to take permanent action to eliminate the problem

Key Activities in D4:

✔ development and verification of root cause through data collection
✔ Review process flow for the location of the root cause
✔ determine the escape point is the closest point in the process where the root cause coulr have been
found
D4 IDENTIFY AND VERIFY ROOT CAUSE AND ESCAPE POINTS

Tool to define and verify root cause and escape point

⮚ Fishborne or Ishikawa diagram]
⮚ Why-Why Analysis
⮚ Check Sheet
⮚ Scatter Diagram
⮚ Process Flow chart
 D5 CHOOSE AND VERIFY PERMANENT CORRECTIVE ACTION
Purpose of D5:
✔ select the best permanent corrective actions to eliminate the root cause in the process.

Key Activities in D5:

✔ Develop and select the solution to remove the root cause and escape point
✔ Verify the effectiveness of the selected solution,

Six Mistakes Proofing Principles

1. Elimination
2. Prevention
3. Replacement
4. Facilitation
5. Detection
6. Mitigation
D6 IMPLEMENT AND VALIDATE PERMANENT CORRECTIVE ACTIONS

Purpose of D6:
✔ plan and implement selected Permanent Corrective Actions

Key Activities in D6:

✔ Implement the best solution to remove the root cause and escape point
✔ Validate the effectiveness of the implemented action
✔ Monitor the effectiveness of the implemented solution and assure that they do not cause any
undesirable effects.
✔ Communicate the plan to all relevant interested parties
 D7: SYSTEM PREVENTION ACTION TO PREVENT RECURRENCE
Purpose of D7:
✔ The purpose of the prevent recurrence is to share the knowledge, preventing problems on similar product,
processes, locations or families.
Key Activities in D7:
✔ review similar products and processes for problem preventive (Horizontal Deployment
✔ To update procedures and work instructions
✔ Assure PFD, PFMEA and Control Plan have been updated
✔ check the needing standization has been identified and implemented
 D8: RECOGNIZE TEAM CONTRIBUTION
Purpose of D8:
✔ Identify the lesson learned and celebrate the success of the team.

Key Activities in D8:

✔ perform a final review of the problem-solving project
✔ Prepare the report for future reference
✔ Document the lesson learned
✔ Before and after comparison of issue
✔ Recognize the team and individual contributions.
 - Identify the Team Originator (Team leader) should
1st Discipline select team members with expertise and involvement
regarding the problem found.

2nd Discipline

- Problem Description : To solve a problem, it must be

precisely defined, the object or part concerned (Model),
location of problem when the problem was discovered
(issue date), how big is the problem (number of failures).
 - Immediate Containment Action: Team or individual should review
installed containment or produce immediate containment actions to protect
customer, assign responsible and date. As well identify actions to take with
suspected product, assign responsible and dates.
Plan

3rd Discipline Do
Team or individual must verify and
validate that containment actions are
NO
effective
Check

Act

Containment
actions
are Effective?

YES
 Occur & Escape root cause:
Team or individual must identify the Occur root cause & Escape root cause,
with help of quality tools and register analysis done.

Plan

4th Discipline Do
Team or individual must verify and
validate both root causes, trough
NO
testing, data analysis, etc
Check

Act

Root causes
verified,
confirmed ?

YES
 Choose & verify corrective action: Team or
individual must analyse, best corrective actions
available, choose the ones that permanantly
eliminates both Occur & Escape root causes
Plan

5th Discipline Do
Tem or individual must verify that the choosen
corrective action eliminates the root causes by NO
testing to failure and the after conditiontion does
not create another effect Check

Act
Corrective
action are
effective ?

YES
 - Implement corrective actions: Team or individual
must assign responsibles & dates to implement the
6th Discipline choosen corrective actions. 8-D originator must give
follow up so they are implemented.

- Choose & Implement Permanent preventive

actions: Team or individual must identify, find,
7th Discipline choose & implement permanent preventive actions,
assign responsibles & dates, Originator must give
follow up so they are implemented.
 B
8-D originator must get the CAR signed by the his
department manager, if we agrees on all the
actions taken.

8-D
report o.k No
?

YES
8D Discipline Team leader (if applicable) ,
congratulates the team , give
appropriate recognition.

8-D Originator must give follow up to the

effectiveness of the corrective actions by
means of the gate chart (Monthly basis)

Originator,
Effectiveness No
of C.A.are
O.K