8D – A disciplined problem solving approach.
8D
is a very common term in problem solving whose purpose is to identify, correct
and eliminate recurring problems. Any internal or external issues can be solved
using an 8D approach. Many OEM’s now a days use 8D for their internal problem
solving and insist their suppliers for following the approach as well. 8D is
based on the logic of PDCA cycle.
·
- History of 8D:
Origin of
8D dates back to 1974 when US Department of Defense released “MIL STD1520” for
Corrective Action and Disposition system for Non confirming materials.
This was
further developed by Ford Motors Company in 1987 and a revised version was
named as Global 8D in 1990.
The 8
disciplines of 8D are as follows:
- · D1: Form a Team
Form a team
of people (usually CFT) with proper product and process knowledge. Operators can also be included in the team as
they have actual processing knowledge.
- · D2: Describe the problem
A problem
should be defined correctly and accurately. The problem description should address
What is the problem, When was it
noticed, Where was it noticed, How many parts have the problem.
- · D2B: Analysis for non detection
Non
detection basically focuses on how the defects get escaped from your final
inspection. Why - Why analysis can be used to identify the root cause for
escape of defect.
- · D3: Immediate Containment Actions
Define and
implement the containment actions to avoid further problems. Generally, the
actions are Hold / Segregate / Rework or
Reject. Actions should be implemented at all places where the parts can be
found for e.g. at customer, WIP, Store, Warehouse etc.
- · D4: Determine Root cause and its analysis (Defect Generation)
This is the
most important stage in 8D methodology. Cause and Effect diagram or Why - Why
analysis can be used for prioritizing possible causes to probable causes and
probable causes to root causes.
- · D5: Define Permanent Corrective Actions
Permanent
corrective actions shall be taken on the root causes identified at both Non
detection and defect generation stages. These actions should be validated to
prevent any further defects and that it resolves the problem.
- · D6: Implement the corrective actions
Implement
the corrective actions taken on the root cause by defining target dates and
responsibilities.
- · D7: Define and Implement Preventive Actions
Preventive
actions are those which are taken on the failure modes of Corrective actions.
In other words, actions taken to prevent the similar failure in future.
Standardize these actions in the system and deploy horizontally to other
similar parts also.
- D8: Congratulate the Team
Recognize
the sublime efforts taken by the team.
- Benefits of 8D:
·
Effective approach towards root
cause analysis and developing proper actions.
·
It also helps to understand why the
problem got escaped.
·
Implementation of corrective and
Preventive actions helps to systemize the actions to prevent similar defects
from occurring.
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