1. 8D Invention
Ford Motor Company started a
problem solving process known as
8D
which takes
8 Disciplines
and uses them to tackle engineering problems
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2. Why to Go ?
• To Eliminate the cause of Detected Non conformity
• To protect the customer from receiving or
using nonconforming product
• Corrective action is taken to prevent recurrence
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3. Why 8D ?
• 8D is a structured approach to solving problems
• Fact Based
Data Collection & Analysis
• Tests progress and results
Verify & Validate
• Documented
History – An information database
Anticipate future problems
Prevent recurrence
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4. 8D Flow
D4:
D5: Choose &
D0: Recognize the Identify Potential
Verify Corrective
Problem Causes
Actions
D6: Implement &
D1: Establish the Select Likely
Validate
Team Causes
Corrective Actions
D2: Describe the D7: Prevent
No Root Cause ?
Problem Recurrence
Yes
D3: Determine and
Implement Identify Possible D8: Congratulate
Containment Corrective Actions the Team
Actions
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5. D0 : Recognize the problem
• Determining the structure of a problem assists in the
selection of the correct tools to use.
• It may give clues to the nature of the root causes
Gradual change , deteriorating performance over time :
Established
Performance
Time
Sudden change , catastrophic change from standard :
Established
Performance
Time
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6. D0 : Continued ..
Start-up, gap between expected and actual performance :
Expected
Performance
Time
Actual
Performance
Recurring change , comes and goes with unknown causes :
Established
Performance
Time
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7. D1 : Establish Team
Establish a small group of people with the knowledge,
time, authority and skill to solve the problem and
implement corrective actions.
The group selects a team leader
• Cross Functional or Multi-Disciplinary
• Process Owner
• Technical Expert
• Others involved in the containment, analysis,
correction and prevention of the problem
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8. D2 : Problem Description
Problem statement = Object + concern + quantification
• Describe the problem in measurable terms.
• Specify the internal or external customer
Remember: A well defined problem is half solved!
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9. D3 : Containment Action
•Define and implement those intermediate actions that
Will protect the customer from the problem
until permanent corrective action is implemented.
•Verify with data the effectiveness of these actions.
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10. D4 : Identify Root Cause
• Identify potential causes which could explain why
the problem occurred.
• Test each potential cause against the problem
description and data.
• Identify alternative corrective actions to eliminate
root cause.
• Tools Used - 5Why ; Fishbone ; Scatter
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11. D5 : Choose and verify Corrective action
• After root causes and possible corrective actions
have been identified, select the corrective actions
that will permanently correct the problem.
• Decision analysis may be needed if the choice is
not obvious.
• Verify that the selected corrective actions will
resolve the problem
•Tools used : Poke – Yoke
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12. D6 : Implement and Validate CA
• Implementation can proceed when best
corrective action has been selected & verified.
• An effective implementation plan reduces
problems.
• Validation is obtained by tracking performance
over time after implementation to ensure the
corrections are permanent.
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13. D7 : Prevent System Recurrence
• Implement the corrective actions in other
potentially affected areas
• Ensure the systems that allowed the problem to
occur and escape have been corrected
• The problem is now Solved & requiring a larger
scale continual improvement project of some type
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14. D8 : Congratulate the Team
• Recognize the collective efforts of your team.
• Publicize your achievement.
• Share your knowledge and learning.
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15. Quick Ponder !!
• What is D Stands for in 8D?
• Who invented in 8D?
• Title 8D ?
Thank you all !!
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