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8D – Eight Disciplines of Problem Solving Process

Course Objectives

Participants can expect to learn and develop skills to confidently:

  • Perform 8D step by step
  • Link 8D to Failure Mode and Effects Analysis (FMEA), Product Development Process and Advanced Product Quality Planning (APQP)
  • Facilitate an effective 8D
  • Participate in 8D exercises
  • Define root causes and mechanisms of failure
  • Set up aCross Functional Team (CFT)
  • Determine effective Interim Containment Action
  • Manage and store 8D content (Lessons Learned) for future use
  • When to select and utilize tools such as:
    • 5 Why
    • Ishikawa/Fishbone
    • Affinity
    • Is / Is Not
    • Statistical Process Control (SPC)
    • Poka Yoke (Error Proofing)
  • Understand links to Control Plan Methodology
  • Complete the 8D format correctly

Course Outline

8D Overview

  • Team Problem Solving Principles
  • Process Description (9 Step Process)
  • Team Structure (Cross Functional Team)
  • Inductive vs. Deductive Problem Solving
  • Change-Induced Problems
  • Never-Achieved Problems

Review of Analytical Tools in 8D

  • Brainstorming Rules
  • Ishakawa / Fishbone
  • Affinity Diagram
  • Control Chart
  • Relationship between 8D and FMEA
  • 5 Why (3-Legged Approach)
  • Interfaces and Noise Factors
  • Error Proofing

8D Process Step by Step

  • D0 – Prepare (Plan) for the 8D
    • Problem Symptom
    • Quantified Symptom
    • Criteria for 8D Continuance
  • D1 – Form the Team
    • Roles and Responsibilities
    • Team Preparation
    • Agenda and Rules
    • Core Team and SMEs
  • D2 – Problem Description
    • Repeated Why
    • Affinity Diagram
    • Is / Is Not
    • Workshop on Problem Statements and Brainstorming
    • Workshop on Problem Description Development
  • D3 – Interim Containment Action (ICA)
  • D4 – Root Cause Analysis (RCA) and Escape Point
    • Human Factors(Operator Error)
    • Comparative Analysis
    • Root Cause Theories
    • Root Cause Verification
    • Escape Point
    • Workshop on Root Cause Theories
  • D5 – Permanent Corrective Action (PCA)
    • Methods for Selecting PCA
    • Error Proofing
    • Verification of PCA
  • D6 – Implementation and Validation of PCA
    • Plan, Do, Study, Act(PDSA) Implementation Plan
    • Change Management
    • Stakeholders
    • Validation Criteria and Sample Size
  • D7 – Prevention Action
    • Processes and Procedures
    • Lessons Learned
  • D8 – Closure and Congratulate the Team
    • Archive of Documents