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
