Introduction to 8D problem solving methodology

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 »

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

64. Videos

65. Free templates

67. Available Trainings Project Management Problem Solving Methodology (8D) Functional Analysis Design FMEA (DFMEA)