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8D Methodology

(Application Approach)

 

 

 

 

Proudly Presented By

Vasanth Thoondimuthu BE (Mech),

Quality Assurance Manager

 

 

Eight Discipline:

D0.Problem statement

D1.CFT Team Formation

D2: Describe the problem.

D3: Develop a temporary containment plan.

D4: Determine and verify root causes.

D5: Verify the permanent solution.

D6: Implement the permanent solution.

D7: Prevent recurrence.

D8: Congratulate your team

D0. Problem Statement

·        What statement you have received from the customer.

 

D0.Problem Statement
Problem Statement		Customer Name
Part Name		Rejected Qty
Part Number		Invoice Details

 

D1.CFT Team Formation:

•      Select people who are all responsible for the problem and or related to that problem.

•      And they have knowledge about that product/processes

 

D1.CFT Members
Name	Department	Designation

 

 

 

 

D2. Describe Problem:

q After the CFT Formation,

q We have to define and describe the problem

q That description gives the answer for the below questions((5W2H)

1.     What,

2.     Where,

3.     When,

4.     Why,

5.     Who, 

6.     How and How many

D2.Problem Description		Part Photo OK	Part Photo Defective
What
Where
When
Why
Who
How

 

D3. Containment Action:

q After Describe the problem,

q We have to define and implement containment actions to isolate the problem from any customer

q Containment action can be taken to protect customers before permanent corrective actions are determined.

q This is a temporary action (temporary correction) Once the Permanent Correct Action is taken it will be removed.

D3.Containment Action
S.No	Location	Interim Containment Action	Resp	Target	Ok Qty	Not Ok Qty

 

D4.Root Cause Analysis:

A.Determine, identify, and verify root causes:

q To identify all applicable causes that could explain why the problem occurred.

q Also identify why the problem was not noticed at the time it occurred.

q All causes shall be verified or proved, not determined by fuzzy brainstorming.

B.Tools Requirement:

D4-1.Brain Storming

D4-2.Cause and Effect Diagram

D4-3.Validation Of Potential Root Cause

D4-4.why why analysis (Occurrence/Non Detection)

D4-1.Brain Storming:

q Group of people get together to generate ideas and solutions

q It contain all possible ideas and solution (but not must be applicable)

q Participants are able to think freely and move into new areas of thought to create N number of new ideas and solutions.

Rules of Brainstorming:

 Below points can help to make successful brainstorming. 

q There is no such thing as a bad or dumb idea   

q Quantity counts – not quality – be creative 

q Capture all the ideas 

q No judgments or criticism.

Rules of Brainstorming:

q Build on other people ideas – combining, expanding, modification is encouraged  

q One conversation at a time

Materials requirement:

q Blank wall space or chart

q Post it notes.

D4-2.Cause and Effect Diagram:

q It is a visualization tool for categorizing the potential causes of a problem

q To categorize the brainstorming causes by Below Categories

ü Manpower/People

ü Machine/Equipment

ü Method/Process

ü Material

ü Environment/ Mother Nature

ü Measurement

D4-3.Validation of Possible Cause:

q  After categorizing the brainstorming causes,

q  We have to validate the causes and we can find out root cause.

D5-1 Validation Of Potential Root Cause
Categories	Root Cause	Specification/Standard	Actual	Significant/ Non Significant
Man
Machine
Method
Material
Environment
Measurement

D4-4.why why analysis (Occurrence/Non-Detection):

q  After find and fix the root cause,

q   We have to do the why-why analysis for Occurrence and Non detection. 

D5: Choose The Permanent Corrective Action:

q  After identified the root cause,

q  Our team should make corrective actions that can be tested for verification.

q  When choosing the corrective action we have to consider the below points.

q  That corrective action should be

ü     Practical

ü     Feasible

ü     Cost-effective

ü     Stable and not fail after implementation

D6. Choose the corrective Action.
S.No	Potential Cause Identified	Action Plan	Responsibility	Target Date
Occurrence:
Detection:

 

D6. Implementation of Permanent Corrective Action:

q After choose corrective action,

q  We have to implement the corrective action plans

q  And continuously follow the action plans up to implement all the action plans,

D6.Choose the corrective Action
S.No	Potential Cause Identified	Action Plan	Responsibility	Target Date	Status
Occurrence :
Detection :

D7.Preventive Action:

q  After  implement the corrective action plans,

q  We have to follow below activities

ü  Update the relevant documents

ü  Monitor the effectiveness

ü  Horizontal Deployment

D7.1 Capitalization of the Documents:

D7-1.Capitalization Of the Documents
S.No	Description	Doc Affected Yes/No	Responsibility	Target Date	Status	Remarks
1	Process Flow	No
2	Work Instruction	No
3	Inspection Standard	No
4	Control Plan	Yes	XXXXX	YYYYYY	Completed
5	FMEA	Yes	XXX	YYYYY	Completed
6	SOP	Yes	XXXXXXX	YYYY	Completed
7	One Point Lesson	Yes	XXXXXX	YYYYYY	Completed
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D7-2. Effectiveness Monitoring:

D7-3. Horizantal Deployment:

D7-3.Horizontal Deployment
S.No	Affected Similar Model	Affected Y/N	Action Plan Dt	Responsibility	Status	Remarks
Updation of Past Trouble data base		Yes	No	Updation of Lesson Learnt		Yes	No

D8. Congratulate the team:

• Celebrate the successful conclusion of the problem-solving effort.
• To provide gifts to encourage the team

Below tools are often used in the 8D methodology for analysis:

ü  Cause and Effect diagrams (Fishbone diagrams)

ü  Pareto charts or Pareto diagrams

ü  5 Why’s

ü  5W and 2H (Who, What, Where, When, Why, How, How often)

ü  Statistical Process Control (SPC)

ü  Scatter plots or scatter diagrams

ü  Design of Experiments (DOE)

ü  Check sheets

ü  Histograms or Capability Analysis

ü  Failure Modes and Effects Analysis (FMEA)

ü  Flowcharts or Process Map