1. Problem solving techniques
Sandeep Bangera
17th May 2013
8D- Methodology

2. 15/2/2012
Gap between existing state and the desired state
Quality
problems
Design
Product Processes
Performance
Conformance
Problem
Efficiency
problem
Unstructured
performance
problem
Source: Quality management journal, Fall 1994
Figure 1: Problem in Quality management
Problem
Problem Problem solving 8D Conclusion 8D-template
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3. Low risk High risk
Simple
When do we apply structured problem solving methods??
Highly Complex
Buying Bread
Baking Bread
Playing Blackjack
Deciding where to
build a factory
Figure 2: Risk and complexity analysis
Problem Solving
Problem Problem solving 8D Conclusion
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8D-template
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4. Figure 3: Shewhart Cycle or Deming’s Cycle
Source: Quality management handbook, pg. 41, Dec . 2005
Problem Solving steps
Problem Problem solving 8D Conclusion
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8D-template
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5. Source: Quality management, 2nd edition, Pearson education, upper saddle river, NJ
Figure 4: Deming’s cycle with tools
Problem Solving steps with tools
Problem Problem solving 8D Conclusion
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8D-template
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6. 1974: Used by US Defence Department in a military standard.
1987: Ford company popularised the 8D concepts
• Preliminary data of the problemD0
• Establishing the TeamD1
• Problem descriptionD2
• Containment actionD3
• Identify the root causeD4
• Identify Permanent Corrective actionD5
• Validating the corrective actionD6
• Prevent recurrenceD7
• Verify and congratulate teamD8
Figure 5: 8D Methodology
Problem Solving Methodology8D
Problem Problem solving 8D Conclusion
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8D-template
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7. D1
Interdisciplinary team with:-
• Right skills
• Experience
• Authority
Objective of team Captain:
• Common goal
Establishing the team
Picture: The zenith of enthusiasm: The strength of team work
Figure 6: Team formation
Problem Problem solving 8D Conclusion
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8D-template
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8. D2 Problem Description
“ A problem well described is half solved”
Problem must be:
• Clearly described
• Scale of problem
• Place of occurrence
• Measurable
• Well communicated
• Tools -WWWWWH, Pareto & control charts
• Mapping out the process with a sketch
Figure 7: Pareto chart
Figure 8: WWWWWH
Problem Problem solving 8D Conclusion
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8D-template
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9. D3 Containment action
Implement containment actions to prevent non-conformance products.
• Company’s end of the line
• Customer side of the line
• Customer stock
• Company’s stock.
D4 Root cause analysis
Why?
To ensure effective corrective action aimed at permanent solution.
How?
Using appropriate systematic approach:-
brainstorming, FMEA, 5 why’s, CE , Is or Is not analysis etc. to identify root cause
Check sheet, histogram, comparison plots etc. to evaluate stratification factors
Problem Problem solving 8D Conclusion
8D Methodology 9
8D-template
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10. Figure 10: Fishbone diagram
Figure 9: 5 Why tool
Root cause analysis tools: 5 why’s, Fishbone diagram etc.
Problem Problem solving 8D Conclusion
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8D-template
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11. • Project management schedule
• Validation of PCA using SPC and FMEA under real test condition.
• If not, revisit step D2-D5.
D5 Identify permanent corrective action (PCA)
• Identify PCA on basis of the root cause analysis.
• Preparation of feasibility study for the PCA
How?
• Solution on basis of root cause.
• Statistical process control (SPC)
• FMEA
D6 Implement & Validating corrective action
Problem Problem solving 8D Conclusion
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8D-template
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12. D7 Prevent recurrence
• Revise the system flow and procedures
• Make system changes to prevent recurrence
• Standardize the new practices
• Notify all departments of the resolution
• Document lesson learnt and archive the document
D8 Congratulate team
• Celebrate your team success
Problem Problem solving 8D Conclusion
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8D-template
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13. Conclusion
•8D methodology is a structured approach of problem solving for quality problems.
•Model can used to solve problems in business operations, Customer complaint,
internal complaints, complaints lodged on the supplier.
• Model raises the level of quality thus reducing the costs of defects.
8D
Problem Problem solving 8D Conclusion
8D Methodology 13
8D-template
Figure 11: 8D methodology
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14. 8D Methodology 14
8D template of company ABB
Problem Problem solving 8D Conclusion 8D-template
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15. Problem Problem solving 8D Conclusion
8D Methodology 15
References
• Gerald F Smith, Quality problem solving, American society of quality, 1998.
• 6ixsigma.org, 8D book,
Available at: http://6ixsigma.org/8d-book.aspx [Accessed: 25 Apr 2013]
• Problem solving, Quality Management handbook, December 2005.
• Uzair Rajput, 8D- problem solving method, Quality management handbook
• Fideltronik, 8D-problem solving methodology
• Marjanca Krajnc, 8D-methodology, Journal of universal excellence, October 2012.
• Bill Arnott, 8D-problem solving methodology, Canada.
• ABB, 8D problem solving template, http://www05.abb.com/global[Accessed: 25 Apr 2013]
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16. Contact Details:
Email: Bangeraj.sandeep@gmail.com