8D REPORT- ( QUALITY )

8D REPORT- ( QUALITY )

Objective:

To identify and verify the root cause(s), implement permanent corrective action and prevent recurrence.

Purpose:

To utilize the Eight Disciplines for the actual problem solving process.

Scope:

The 8D problem solving tool is primarily intended to resolve a problem when the “cause is un known”. This also can be used when the “cause is known” and the problem needs to be approached in detail and monitor its effectiveness.

Guidelines:

D0 – Symptom:

What customer first observed the defect? Or

            What is the problem definition in customer terms?

D0 – Emergency Response action:

            What is the immediate action?

The emergency actions like,

            1.         Make air shipment of good pieces to avoid assembly stop.

            2.         Stop the current process/ communicate to Supplier about the problem.

D1 - TEAM:

Establish a small group of people with the process/product knowledge, allocated time, skill, and authority in the required technical disciplines to solve the problem and implement corrective actions.

Champion: The champion, who is closest to the problem, has the resources, power, and influence to get the problem solved.

Leader: The leader is a group member who ensures the group performs its duties and responsibilities. The leader is the spokesperson for the team, calls the meetings, establishes a meeting time and directs the meeting to follow the agenda. The leader is the day-to-day authority, is responsible for over all coordination, and assists the team to set its goals and objectives. Team and ensuring the 8D information is recorded. Identify the Management Owner, who will accept overall responsibility for the process. A Facilitator, trained in problem solving processes, should guide teams.

Members: The people who are affected by the problem are the team members. The team members responsible for respecting others ideas, keeping an open mind, being respective to consensus decision making, and listening actively to others ideas. All members must be clear in their understanding of assignments and accept them willingly.

 D2 – PROBLEM DESCRIPTION:

Specify the internal/external customer problem by identifying in quantifiable terms, which will answer the questions: Who? What? When? Where? Why? How? and How Many?

What   - What is the extent of the problem?

Why    - Any explanation/reason contributing to the problem should be stated.

Where            - Where is the defect located?

Who    - Identify the individuals associated with the problem? Identify the customer.

When  - Identify the time the problem started and its occurrence in earlier time periods. What time of the year does the problem occur?

How    - In what mode of operation did the problem occur? What procedures were used?

How many     - How many times the problem occurred?

                          Quantify the problem.

D3 - IMPLEMENT INTERIM (CONTAINMENT) ACTION:      

Define and implement containment actions to isolate the effect of the problem from any internal or external customer until corrective action are implemented and monitored its effectiveness. Verify the effectiveness of the containment actions.

The containment actions like        1). 100% sorting,

2). Inspection before shipment,

3). Introduce additional process.

D4 – ROOT CAUSE (S):

Identify all potential causes, which could explain why this problem occurred. Isolate and verify the root cause by testing each potential cause against the problem description and test data. Identify alternative corrective actions eliminate root causes. 

Identify the potential causes:

1). Identify all probable potential causes. Develop a plan for investigating each cause, and update the action plan.

2). Evaluate a potential cause against the problem description.

Analyze Potential causes:

1). Use the iterative process to analyze each potential cause using data collection, analysis.

2). Investigate all potential causes independently

Validate root causes:

1). Clearly state root cause(s) and identify data, which suggests a conclusion.

2). Verify root cause factors are present in the process.

D5 – CHOOSE AND VERIFY CORRECTIVE ACTION (S):

Through pre-production test programs quantitatively confirm that the selected corrective actions will resolve the problem for the customer, and will not cause any undesirable side effects. Define contingency actions, if necessary, based on risk assessment.

A detailed verification / action plan is required to outline WHO will be taking WHAT actions by WHEN. The action plan should show what data or statistics will be collected and analyzed, who is responsible and track actual progress and scheduled completion. All verification of the problem solution will require decision-making. Verify each corrective actions before the actions are implemented.

D6 - IMPLEMENTED PERMANENT CORRECTIVE ACTION (S):

            Define and implement the best permanent corrective actions. Choose on-going controls to ensure the root cause is eliminated. Once in production, monitor the long-term effects and implement contingency actions, if necessary.

·         Establish an action plan on all permanent actions.

·         Establish on-going controls on the process.

·         Begin a statistical plan to measure the effectiveness of the corrective actions.

·         Identify the contingency actions

Establish verification method and a planned date when it will be implemented to confirm that the implemented actions were effective and provide the expected results. Assign qualified verification personnel. Verification personnel shall document evidence concerning the corrective action’s success or lack of. If successful, signs and dates the form.

D7 – PREVENTIVE ACTION (S):

Modify the management systems, operating systems, practices, and procedures to prevent recurrence of this and similar problems. Identify opportunities for improvement and establish a process improvement initiative.

·         Prepare a process flow diagram of the management /operating system that should have prevented the problem and all similar problems.

·         Make needed changes to the system. Address system follow-up responsibilities.

·         Standardize practices.

·         Use action plan to coordinate required actions.

·         Out line the reasons why this problem occurred.

-          Cause and Effect diagram.

-          Process flow diagram.

·         Help managers understand why their system allowed a problem to develop.

·         Revise management systems, practices, and procedures, if necessary.

·         Document new standard procedures, streamline to remove obsolete procedures and revise previous standards.

D8 – TEAM AND INDIVIDUAL RECOGNITION:

            Recognize the collective efforts of the team.

• Recognize the team’s collective efforts in solving the problem.
• Document what was learned in solving the problem.
• Write case study reports.
• Acknowledge the significance and value of the problem solution.

Cycle time to complete the 8D (CORRECTIVE AND PREVENTIVE ACTION):

Maximum Time                     Discipline

2 Weeks                     -           D0 – D4

10 Weeks                   -           D4 - D8