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8D Problem Solving - Automotive Industry
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Introduction to 8D problem solving methodology.
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8D Problem Solving - Automotive Industry
1.
8D Problem Solving
Automotive Industry
2.
Introduction 2 words
would summarize this presentation : Gemba (現場) 8D
3.
Introduction Gemba (現場)
« Actual location of the issue »
4.
5.
Gemba Attitude
6.
8D =
8 Do = 8 Disciplines = 8 Steps
7.
8D: Systemic
problem solving methodology, introduced by Ford Motor Company late 80’s
8.
Do 1: Establish
a team
9.
As soon as
a customer claim is received, establish a multi-skilled team
10.
Multi-skilled: Quality, Process
Engineering, Production Engineering, R&D, Lab
11.
And most important:
a line member
12.
Do 2: Define
the problem
13.
« A problem well
stated is a problem half solved »
14.
WWWWWH: Who, What,
Where, When, Why, How
15.
Pareto Also called
80-20 rule
16.
Support your problem
description by a picture or a sketch
17.
Gemba : Recover
as much as required defective parts
18.
Duplication Tests: Try
to reproduce the issue
19.
Red Rabbit :
Pass the defective part through the process
20.
Do 3: Implement
Containment
21.
Containment consist in
stopping the bleeding…
22.
… through stock
sorting
23.
… rework,
24.
… enhanced end
of line check, etc.
25.
Once containment is
agreed among the team, …
26.
It is necessary
to validate it: FMEA, Function, Durability, etc
27.
Once validated, implementation
follows steps …
28.
Step 1 :
Implement at Customer side of the line
29.
Step 2 :
Implement at customer stocks
30.
Step 3 :
Implement at supplier (your) stock
31.
Step 4 :
Implement at your End Of Line
32.
Step 5 :
Include containment into manufacturing process
33.
Do 4: Identify
root cause
34.
Make sure you
are looking for root-cause !
35.
Most known example
is engine oil level issue …
36.
… instead of
looking for oil leakage underneath the vehicle, member just add oil !
37.
Few methods would
support your root-cause analysis …
38.
Ishikawa: Cause-Effect Diagram,
6M, Fishbone Diagram Machines Methods Materials Measurement Personnel Environment
39.
5 why’s :
Ask as much as required the question « Why ?»
40.
Failure Tree Analysis
(FTA)
41.
Reverse Engineering: Part
by part disassembly until identifying root-cause
42.
Do 5: Choose
and verify Permanent Corrective Actions (PCAs)
43.
Once root-cause identified,
44.
PCAs are agreed
within the team…
45.
Once again, validation
is a must: FMEA, Function, Durability, etc
46.
Do 6: Implement
PCAs
47.
Implementation = Project
Management
48.
Do 7: Prevent
recurrence
49.
Identify lessons learned
50.
Update procedures &
documents
51.
Including DFMEA and
Control Plan Update procedures & documents
52.
#8 Congratulate the
team!
53.
Tips & Tricks
before Conclusion
54.
Tips & Tricks
before Conclusion Speak with facts !
55.
Tips & Tricks
before Conclusion Don’t judge. Don’t blame.
56.
Tips & Tricks
before Conclusion ( Visualize ) ( Visualize)
57.
Tips & Tricks
before Conclusion Example of visualization
58.
Tips & Tricks
before Conclusion Example of visualization
59.
Tips & Tricks
before Conclusion Example of visualization
60.
Conclusion Conclusion
61.
Conclusion Gemba =
A mindset 8D = A discipline
62.
Thank you for
your attention Thank you for your attention
63.
64.
Videos
65.
Free templates
66.
67.
Available Trainings Project
Management Problem Solving Methodology (8D) Functional Analysis Design FMEA (DFMEA)
68.