Post on 10-Apr-2018
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When to Use 8D?
When the root cause is not known.
When the problem is complex.
When the severity and impact of the problem ishigh.
When the problem cannot be solved by one
person alone.
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D 1: Form the Team
Define Team Roles.
Provide Inputs to Team.
Establish Ground Rules and Disciplines.
Initiate Problem Solving Report.
Problem Solving Checklist.
Establish the Team.
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D 1: Form the Cross Functional Team
Establish the Team:
Team Size should be between 4 and 9.
Members should be selected from right levels
in the organization. Members should include those who are
affected by the problem.
Members should include people who might
have controls in the areas originating theproblem.
Members should include persons having
specialist knowledge in the areas of problem.
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D 1: Form the Cross Functional Team
Tasks: To approve resources.
To Guide, Motivate, Coach Team Members.
To Plan and Lead the Team. To Manage the Problem Solving Process.
To contribute in problem solving based on
knowledge and expertise.
To document and communicate progress.
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D 1: Form the Cross Functional Team
Define Team Roles:1. Champion: Champion is the designated member of the
management.
The Champion has the authority to sanction
improvements, provide resources. Responsibilities of the Champion include: To
Guide, Direct, Motivate, Train Coach the TeamMembers and to Advocate to UpperManagement.
2. Team Leader: The Team Leader is experienced in ProblemSolving.
The Team Leader is Responsible for Planning,Coordinating, Monitoring and Ensuring Progressin Problem Solving.
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D 1: Form the Cross Functional Team
Define Team Roles:3. Facilitator:
The Facilitator may not have knowledge of theproblem, but is intimately familiar with theProblem Solving Process.
The facilitator helps the Team through theProblem Solving Process.
4. Recorder: The Recorder documents each Step of the
Problem Solving Process and communicates toall concerned parties.
5. Members: Members contribute at each step of Problem
Solving based on their knowledge and expertise.
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Inputs to Team
Team
Field
Report
Efficiency
and success
of the
projectdepends on
how much
relevant
informationis available
right from
the
beginning.
Issues reported
From Internal
Customers
Road
Trips
Dealer
Comments
Fleet Operator
Comments
Input from
QFD
D 1: Form the Cross Functional Team
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Establish Ground Rules and Disciplines
Determine decision making rules: Consensus; Majority.
Establish meeting disciplines:
Team Roster.
Meeting Calendar.
Meeting Agenda.
Action Plan.
Documentation. Launch the Process.
Initiate the Problem Solving Report.
Establish Team Goals before considering
methods and resources.
D 1: Form the Cross Functional Team
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Contents:
Problem statement guidelines.
Update Problem Solving Report.
D 2: Describe the Problem
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Problem statement guidelines :
Use 5W/2H Questions.
Use 5 Why Questions.
D 2: Describe the Problem
Who? What? When? Where? Why?How?How
Many?
Why?
Why?
Why?
Why?
Go till Dont know. State the Problem, including the last
known Why.
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Contents:
Containment.
Protect the Customer.
Verification.
Update Problem Solving.
D 3: Contain Symptom
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Containment :
Contain the Symptom flow.
Stop defect at each point in the process.
Validate that the action taken is fully effective.
D 3: Contain Symptom
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Protect the Customer :
The principal objective of containment is toprotect the customer from experiencing additional
problems.
D 3: Contain Symptom
Sort 100%.100% review by subsequent operation.
100% inspection prior to shipment.
Verify actions.
Manufacturing
Process
Engine Testing
ProcessAssembly
Process
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Update Problem Solving :
Document containment plan and
implementation in the Problem Solving Report.
D 3: Contain Symptom
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Contents:
Identify Potential Root Causes.
Identify what has changed.
Test for Root Causes.
Types of Root Causes.
Update Problem Solving Report.
D 4: Find and Verify Root Cause
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Why Why Analysis :
D 4: Find and Verify Root Cause
Sym
pto
m
Why? Why? Why? Why? Why?
(Root
Cause
)
Fiel
d
Che
ck
Std.
Exis
ts?
Appl
ied?
Acti
on
SOP
Exis
ts?
Appl
ied?
Acti
on
Not
True
True
True
True
Not
True
Not
True
Y
N
Y
NRest
ore
Y
N
Y
N
Revi
ew
Apply
-Dev
New
SOP
-Dev.
New
Std.
Revi
ew
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Identify Potential Root Causes :
Brainstorm using Cause and Effect Diagram.
D 4: Find and Verify Root Cause
ManMachine/ tool
Material Method
Environment
ManMachine/ tool
Material Method
EnvironmentProblem
Symptom
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Identify what has changed :
New supplier?
New Raw Material?
New Inspection Plan?
New Handling, Storage and Preservation
System?
Process Change?
New Tool?
New Method?
New Operator?
D 4: Find and Verify Root Cause
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Test for Root Causes :
Gemba Test.
A simple inspection of existing data, actual
situation might be all that is necessary to
confirm that a potential Cause is a RootCause.
Conduct Designed Test.
Regression Analysis of Data. Designed Experiment with One Factor.
Designed Experiment with Several Factor.
D 4: Find and Verify Root Cause
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Types of Root Causes :
Occurrence Root Cause.
Occurrence Root Cause actually causes the
problem.
Detection Root Cause.
Detection Root Cause allows the problem to
escape detection.
System Root Causes. System Root Cause causes both occurrence
and detection root causes.
D 4: Find and Verify Root Cause
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Update Problem Solving Report :
Document containment plan and
implementation in the Problem Solving Report.
D 4: Find and Verify Root Cause
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Contents:
Elimination of root Cause.
Identify Alternative Potential Corrective
Actions.
Select the Best Alternatives from the Potential
Corrective Actions.
Validate Selected Corrective Action.
Update Problem Solving Report.
D 5: Select Permanent Corrective Action
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Elimination of root Cause :
The first priority of Permanent CorrectiveAction is to eliminate the identified root causes.
There could be several alternative potential
actions for eliminating a single root cause.Each of them are Potential Corrective Actions.
We need to identify the alternative potentialcorrective actions and choose the best among
them.
D 5: Select Permanent Corrective Action
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Identify Alternative Potential Corrective
Actions : A Tree Diagramme may be used for identifying
alternative potential corrective actions.
D 5: Select Permanent Corrective Action
Root Cause 1
Potential Corrective
Action 1.1
Potential Corrective
Action 1.2
Potential Corrective
Action 1.3
Root Cause 2
Potential Corrective
Action 2.1
Potential Corrective
Action 2.2
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Select the Best Alternatives from the
Potential Corrective Actions :
Use process knowledge of the Team Members
to identify the best alternative from the
potential corrective actions. If required, develop criteria for selecting the
best one.
D 5: Select Permanent Corrective Action
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Validate Selected Corrective Action :
Run Pilot Test.
Verify that another problem is not generated
by the solution.
Monitor Results.
Quantify changes in key indicators.
D 5: Select Permanent Corrective Action
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Update Problem Solving Report :
Document containment plan and
implementation in the Problem Solving Report.
D 5: Select Permanent Corrective Action
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Contents: Plan and Organize Implementation.
Implement Permanent Corrective Action.
Update Problem Solving Report.
D 6: Implement Permanent Corrective
Action
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Plan and Organize Implementation :
Identify the tasks.
Determine Timing.
Assign responsibilities.
Document Plan.
D 6: Implement Permanent Corrective
Action
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Implement Permanent Corrective Action :
Prepare for Change.
What will be the impact?rts. Who will be affected?
What training will be required?
What resources will be required? Track Progress.
Trend Charts.
D 6: Implement Permanent Corrective
Action
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Update Problem Solving Report :
Document containment plan and
implementation in the Problem Solving Report.
D 6: Implement Permanent Corrective
Action
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Contents:
Review Quality System and Change/Update
systems and documents.
Look for New Opportunities.
Update Problem Solving Report.
D 7: Prevent Recurrence
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Review Quality System and Change/Update
systems and documents :
Review Policy Statements.
Review Procedures and Work Instructions.
Review FMEA, Control Plan, Check sheets. Change/update system and documents in order
to prevent recurrence.
Update Change Control Records.
D 7: Prevent Recurrence
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Look for New Opportunities : Review Similar Processes.
Review Other Parts.
Review Other Locations. Look for the opportunities for implementing the
lessons learnt from the current project and
initiate actions accordingly.
D 7: Prevent Recurrence
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Update Problem Solving Report :
Document containment plan and
implementation in the Problem Solving Report.
D 7: Prevent Recurrence
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Contents:
Congratulate the Team.
Update Problem Solving Report.
D 8: Congratulate the Team
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Congratulate the Team :
Highlight creative solutions taken by the Team
during the project.
Appreciate individual Team Members for theirrespective contributions.
Learning from the project.
Send communication through all internal media,
House Magazine, Displays.
D 8: Congratulate the Team
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Update Problem Solving Report :
Document containment plan and
implementation in the Problem Solving Report.
D 8: Congratulate the Team