problem solving skills 8d

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• What is 8D? A template for efficient pr ...

What is 8D? A template for efficient problem-solving

How you respond when problems arise is one of the most defining qualities of a manager. Luckily, there are tools you can use to master problem-solving. The 8D method of problem-solving combines teamwork and basic statistics to help you reach a logical solution and prevent new issues from arising.

You’ve spent months overseeing the development of your company's newest project. From initiation, planning, and execution, you’re confident this may be your best work yet.

Until the feedback starts rolling in.

There’s no sugar-coating it—things don’t always go as planned. But production or process issues are hardly a signal to throw in the towel. Instead, focus on honing your problem-solving skills to find a solution that keeps it from happening again. 

The 8D method of problem solving emphasizes the importance of teamwork to not only solve your process woes but prevent new ones from occurring. In this guide, we’ll break down what 8D is, how to use this methodology, and the benefits it can give to you and your team. Plus, get an 8D template to make solving your issue easier. 

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What is 8D?

The eight disciplines (8D) method is a problem-solving approach that identifies, corrects, and eliminates recurring problems. By determining the root causes of a problem, managers can use this method to establish a permanent corrective action and prevent recurring issues. 

How do you use the 8D method?

The 8D method is a proven strategy for avoiding long-term damage from recurring problems. If you’re noticing issues in your workflow or processes, then it’s a good time to give this problem-solving method a try. 

To complete an 8D analysis, follow “the eight disciplines” to construct a statistical analysis of the problem and determine the best solution.

The eight disciplines of problem-solving

8D stands for the eight disciplines you will use to establish an 8D report. As you may notice, this outline starts with zero, which makes nine total disciplines. The “zero stage” was developed later as an initial planning stage. 

To illustrate these steps, imagine your organization experienced a decline in team innovation and productivity this past year. Your stakeholders have noticed and want to see changes implemented within the next six months. Below, we’ll use the 8D process to uncover a morale-boosting solution.

D0: Prepare and plan

Before starting the problem-solving process, evaluate the problem you want to solve. Understanding the background of the problem will help you identify the root cause in later steps. 

Collect information about how the problem has affected a process or product and what the most severe consequences may be. Planning can include:

Gathering data

Determining the prerequisites for solving the problem

Collecting feedback from others involved

If we look back at our example, you may want to figure out whether this decline in morale is organization-wide or only applies to a few departments. Consider interviewing a few employees from different departments and levels of management to gain some perspective. Next, determine what knowledge and skills you will need to solve this lapse in productivity. 

D1: Form your team

Create a cross-functional team made up of people who have knowledge of the various products and workflows involved. These team members should have the skills needed to solve the problem and put corrective actions in place. 

Steps in this discipline may include:

Appointing a team leader

Developing and implementing team guidelines

Determining team goals and priorities

Assigning individual roles

Arranging team-building activities

From our example, a solid team would consist of people with first-hand experience with the issues—like representatives from all departments and key people close to workshop-level work. You may also want to pull someone in from your HR department to help design and implement a solution. Most importantly, make sure the people you choose want to be involved and contribute to the solution.

D2: Identify the problem

You may have a good understanding of your problem by now, but this phase aims to break it down into clear and quantifiable terms by identifying the five W’s a and two H’s (5W2H):

Who first reported the problem?

What is the problem about?

When did it occur and how often?

Where did it occur (relating to the sector, supplier, machine, or production line involved)?

Why is solving the problem important?

How was the problem first detected?

How many parts/units/customers are affected?

Use your team’s insights to answer these questions. From our example, your team may conclude that: 

Employees feel overwhelmed with their current workload. 

There is no real structure or opportunity to share new ideas.

Managers have had no training for meetings or innovation settings.

Disgruntled employees know they can achieve more—and want to achieve more—even if they seem disengaged.

Once you answer these questions, record an official problem statement to describe the issue. If possible, include photos, videos, and diagrams to ensure all parties have a clear understanding of the problem. It may also help to create a flowchart of the process that includes various steps related to the problem description.

D3: Develop an interim containment plan

Much like we can expect speedy first aid after an accident, your team should take immediate actions to ensure you contain the problem—especially if the problem is related to customer safety. 

An interim containment plan will provide a temporary solution to isolate the problem from customers and clients while your team works to develop a permanent corrective action. This band-aid will help keep your customers informed and safe—and your reputation intact.

Because your findings revealed workers were overworked and managers lacked training, your team suggests scheduling a few mandatory training sessions for leaders of each department covering time and stress management and combating burnout . You may also want to have a presentation outlining the topics of this training to get key managers and stakeholders interested and primed for positive upcoming changes. 

D4: Verify root causes and escape points

Refer back to your findings and consult with your team about how the problem may have occurred. The root cause analysis involves mapping each potential root cause against the problem statement and its related test data. Make sure to test all potential causes—fuzzy brainstorming and sloppy analyses may cause you to overlook vital information. 

In our example, focus on the “why” portion of the 5W2H. You and your team identify six root causes:

Managers have never had any training

There is a lack of trust and psychological safety

Employees don’t understand the objectives and goals

Communication is poor

Time management is poor

Employees lack confidence

In addition to identifying the root causes, try to pinpoint where you first detected the problem in the process, and why it went unnoticed. This is called the escape point, and there may be more than one. 

D5: Choose permanent corrective actions

Work with your team to determine the most likely solution to remove the root cause of the problem and address the issues with the escape points. Quantitatively confirm that the selected permanent corrective action(s) (PCA) will resolve the problem for the customer. 

Steps to choosing a PCA may include:

Determining if you require further expertise

Ensuring the 5W2Hs are defined correctly

Carrying out a decision analysis and risk assessment

Considering alternative measures

Collecting evidence to prove the PCA will be effective

Your team decides to roll out the training used in the interim plan to all employees, with monthly company-wide workshops on improving well-being. You also plan to implement meetings, innovation sessions, and team-coaching training for managers. Lastly, you suggest adopting software to improve communication and collaboration. 

D6: Implement your corrective actions

Once all parties have agreed on a solution, the next step is to create an action plan to remove the root causes and escape points. Once the solution is in effect, you can remove your interim containment actions.

After seeing success with the training in the interim phase, your stakeholders approve all of your team’s proposed PCAs. Your representative from HR also plans to implement periodic employee wellness checks to track employee morale .

To ensure your corrective action was a success, monitor the results, customer, or employee feedback over a long period of time and take note of any negative effects. Setting up “controls” like employee wellness checks will help you validate whether your solution is working or more needs to be done. 

D7: Take preventive measures

One of the main benefits of using the 8D method is the improved ability to identify necessary systematic changes to prevent future issues from occurring. Look for ways to improve your management systems, operating methods, and procedures to not only eliminate your current problem, but stop similar problems from developing later on.

Based on our example, the training your team suggested is now adopted in the new manager onboarding curriculum. Every manager now has a “meeting system” that all meetings must be guided by, and workloads and projects are managed as a team within your new collaboration software . Innovation is improving, and morale is at an all-time high!

D8: Celebrate with your team

The 8D method of problem-solving is impossible to accomplish without dedicated team members and first-class collaboration. Once notes, lessons, research, and test data are documented and saved, congratulate your teammates on a job well done! Make an effort to recognize each individual for their contribution to uncovering a successful solution.

8D report template and example

Check out our 8D report template below to help you record your findings as you navigate through the eight disciplines of problem solving. This is a formal report that can be used as a means of communication within companies, which makes for transparent problem-solving that you can apply to the entire production or process chain.

Benefits of using the 8D method

The 8D method is one of the most popular problem-solving strategies for good reason. Its strength lies in teamwork and fact-based analyses to create a culture of continuous improvement —making it one of the most effective tools for quality managers. The benefits of using the 8D method include: 

Improved team-oriented problem-solving skills rather than relying on an individual to provide a solution

Increased familiarity with a problem-solving structure

A better understanding of how to use basic statistical tools for problem-solving

Open and honest communication in problem-solving discussions

Prevent future problems from occurring by identifying system weaknesses and solutions

Improved effectiveness and efficiency at problem-solving

Better collaboration = better problem solving

No matter how good a manager you are, production and process issues are inevitable. It’s how you solve them that separates the good from the great. The 8D method of problem solving allows you to not only solve the problem at hand but improve team collaboration, improve processes, and prevent future issues from arising. 

Try Asana’s project management tool to break communication barriers and keep your team on track.

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8D Problem Solving: A Step-by-Step Guide

8D problem solving is an excellent framework for addressing complicated manufacturing problems and beyond. I’ve watched it turn around many a troubled production line. It’s a systematic way to analyze a problem step by step and ensure you don’t miss anything. You’ll learn to build the right team, determine the root causes, and fix the problems for good. So, here are the specifics of the framework.

What is 8D Problem Solving?

Ford Motor Company developed the 8D model in the 1980s, originally called Team Oriented Problem Solving (TOPS). However, the company borrowed the structure from earlier problem-solving processes implemented by the U.S. government and military.

At its essence, 8D adheres to these core principles:

• Team-oriented problem solving
• Data-driven decision making
• Root Cause Analysis
• Permanent corrective action
• Prevent recurrence

You’ll see 8D utilized throughout various industries, including:

• Automotive manufacturing
• Electronics
• Food manufacturing

Implementing 8D delivers numerous benefits. You’ll observe higher product quality, lower costs, and improved customer satisfaction. Plus, it instills a culture of continuous improvement in your company.

In my consulting experience, companies that embrace 8D experience fewer recurring problems. In other words, you’re not just solving problems – you’re also stopping them from coming back.

The 9 Steps of 8D Problem Solving

Originally, the process consisted of 8 steps. However, a planning step (D0) was later added to the beginning of the process, making it a 9-step approach. Let’s discuss each step:

• D0: Plan and Prepare
• D1: Build the Team
• D2: Define the Problem
• D3: Stop the Current Problem from Getting Worse
• D4: Find and Verify the Root Cause
• D5: Implement Permanent Corrective Actions
• D6: Implement and Validate the Solution
• D7: Prevent Problem from Recurring
• D8: Congratulate the Team and Turn the Game off

Each step is essential to solving the problem at hand. You cannot skip any steps, nor should you rush through them. Companies will always come up with a reason to shorten the process—but it never fails to result in an incomplete solution or the problem arising again.

The D0 step, in particular, is of utmost importance, as executing the step ensures you have the resources, data and political support to solve the problem as you now intend to.

When I do consulting work, I preach this methodical approach to problem solving. Using this structured approach will make you a more thorough and effective problem solver.

Forming the 8D Team (D1)

Building the right team is essential to effective 8D problem solving. You need a combination of skills, expertise, and viewpoints, as 8D problem solving deals with complex issues.

In 8D problem solving, the core team is usually 3 people for data analysis and a larger team of subject matter experts when you need to brainstorm or experiment. This two-tier team structure enables effective data analysis and broader brainstorming or experimentation.

When selecting your team, consider the following:

• Relevant technical expertise
• Problem-solving skills
• Communication skills
• Availability to participate throughout the process

It’s important to have clear team members and roles defined. You should have:

• A team leader to guide the process
• A recorder to document any findings and actions
• Subject matter experts

Diverse cross-functional teamwork is essential. If teams are too homogeneous, I’ve noticed that they struggle to find the right solution. You need different insights to collectively challenge assumptions and recognize innovative solutions.

Team size is another consideration. I’ve found that a core team of 3 to 5 people works well. If you have too many people, the process becomes cumbersome and slow.

Describing the Problem (D2)

To define the problem accurately, look at the following:

• Quantitative data (measurements, frequencies, costs)
• Qualitative data (customer complaints, any anecdotal information)
• The “5 W’s and 1 H” (Who, What, When, Where, Why, How)
• A problem statement that is specific, measurable and ideally objective

If the problem could be interpreted as a vague or subjective statement, it isn’t specific enough. For example, “Quality is bad” isn’t specific enough. “We’re finding that 10% of all weld joints are failing inspection due to surface defects” is specific enough.

This is where the actual data comes into play. Look at the data both quantitatively and qualitatively. What are you seeing that tells you you have this problem? Then, what are those numbers saying with respect to patterns, trends or anomalies? This will help you determine the real problem you’re dealing with.

Remember: A problem well-stated is a problem half-solved. If you have to go back and redefine it later, you’ll waste a lot of time and energy on the later steps of the 8D process.

Implementing Interim Containment Actions (D3)

Containment actions are short-term steps that prevent the customer from feeling the problem’s impact. These aren’t true solutions, but they allow you time to identify and implement permanent solutions.

Common types of interim containment actions include:

• Increased inspection
• Sorting suspect product
• Process changes
• Customer communication
• Temporary design changes

The key with these actions is speed. You should do everything in your power to stop the customer from feeling the pain. Many companies get stuck at this phase, worrying about the cost or admitting there’s a problem. This short-term thinking always results in bigger headaches later.

Assess whether your containment actions are effective. Are they truly stopping the problem from reaching the customer? If not, how can you adjust or add another containment action?

Thoroughly document all of your containment actions. You’ll use this information later to develop permanent solutions and ensure the problem doesn’t happen again.

Identifying and Verifying Root Causes (D4)

Root cause analysis is the process of delving deep to discover why a problem truly occurred. It’s not about who is to blame – it’s about understanding why the problem occurred in the first place.

The method uses a variety of problem-solving tools, including:

• Fishbone diagrams
• Pareto charts
• Failure Mode and Effects Analysis (FMEA)
• Statistical process control

Personally, I’ve found the 5 Whys to be particularly helpful. This involves asking “why” multiple times to get to the root cause of a problem. It’s a very basic strategy, but it’s surprisingly effective.

A common mistake to avoid is confusing symptoms with causes. For example, “operator error” is almost never the root cause of a problem. You need to dig deeper to figure out why the operator made an error. Was it due to a lack of training? Poorly written instructions? Bad equipment design?

Once you have a list of potential causes, verify them through data analysis. Can you recreate the problem using the suspected cause? Can you prevent the problem by controlling the cause?

This step can be tedious and requires patience. Don’t accept the first explanation you come across. Keep asking “why” until you’re confident you’ve found the true root cause.

Developing Permanent Corrective Actions (D5)

Now that you’ve identified the root cause, it’s time to brainstorm permanent solutions. This is the fun part where you get to be creative and innovative.

The most effective corrective actions will:

• Address the root cause of the problem.
• Be possible to execute.
• Not create other problems.
• Prevent the issue from happening again.

Gather your team and brainstorm potential solutions. It’s important to encourage creativity here. Some of the best solutions I’ve seen have come from someone who wasn’t directly involved in the problem.

Evaluate each potential solution based on your criteria. Also, evaluate the long-term impact of the solution. It’s easy to fall into the trap of implementing a quick fix, so ask yourself, “Will this solution truly prevent the issue from happening again?”

Include the people who will execute the solution in the brainstorm. This might be the line operator, an engineer, a quality person, etc. The people closest to the problem will often have the best solutions.

Remember, the objective is to solve the problem forever. Don’t allow the team to implement a solution that will only fix the problem for now.

Implementing and Validating Solutions (D6)

The 8D framework places a strong emphasis on using data and quantitative analysis to verify that your selected corrective actions will actually fix the problem. To do this, set up measurements and define what success looks like before implementing your solutions.

When you implement your solutions:

• Create a detailed plan of attack.
• Assign each step to an owner along with a due date.
• Communicate changes to everyone who needs to know.
• Train people or provide resources so they can execute your solution.
• Monitor the implementation process closely.

After implementing your solutions, verify that they actually worked. Are you seeing the improvements you expected? If not, you may need to revisit your solution.

Thoroughly document all of the changes you made. This documentation is essential for creating standard operating procedures, training new hires, and making sure the issue never happens again.

In my consulting content, I constantly reinforce the importance of verifying that your solutions worked. Don’t just assume they did – show it with data.

Preventing Problem Recurrence (D7)

Prevention is about implementing systemic changes so the issue doesn’t happen again. It’s a step many people forget, but it’s arguably the most important.

Here are a few prevention strategies:

• Update procedures and standards
• Add error proofing
• Enhance training
• Improve communication
• Change design or manufacturing

Think conceptually about the issue. What other processes or products might have the same problem? If so, make sure to prevent it there as well.

Training is often the solution. Make sure all relevant employees understand the issue, why it happened, and how to prevent it from happening in the future.

Set up continuous improvement processes. Preventative checks, audits, process reviews, and feedback loops help you catch issues before they become huge problems.

I’ve also witnessed companies change their entire business with effective prevention. It’s not just about fixing issues – it’s building a quality and continuous improvement culture.

Recognizing the Team and Closing the Process (D8)

The eighth and final step of the 8D methodology is often neglected, yet it is key to long-term success. Recognizing the team’s efforts and formally closing the process yields closure and encourages future engagement.

When recognizing the team:

• Recognize individual team members
• Celebrate the team’s success and learnings
• Explain the impact of their work
• Contemplate offering formal recognition or rewards

Capture lessons learned. What worked well? What didn’t? This learning is invaluable for future problems that arise.

Communicate success stories to your entire organization. This step generates additional buy-in for continuous improvement and motivates other teams.

Formally close the 8D process. This action signifies the end of immediate problem solving and the beginning of ongoing monitoring and improvement.

In my experience, teams that feel recognized are more engaged and hungry for the next problem to solve. Once you play this last step, you’ll realize the ROI of 8D again and again.

Tools and Techniques for 8D Problem Solving

Effective 8D problem solving requires various tools and techniques. The 8D process itself is a methodology, so training in the 8D process and various data analysis tools is necessary to effectively execute the process.

Common 8D tools include:

• 5 Why analysis
• Scatter plots
• Control charts

Using the right tool for each step is critical. For example, you might use a Pareto chart to prioritize issues in the problem description step and a fishbone diagram to identify potential root causes.

The key to making these tools work in the 8D process is to ensure the 8D process integrates them. They’re not tools sitting in isolation from one another; they all fit together to create a comprehensive problem-solving strategy.

Training is also key to effectively using the tools. I’ve seen many teams struggle with the 8D process simply because they didn’t have the data analysis tools down pat. So, invest in training for your team members to make the problem solving process itself more effective.

8D Reporting and Documentation

An 8D report is how suppliers communicate with customers about what they have done to address a complaint. Therefore, it’s an essential communication piece in the 8D process.

The key to a great 8D report is:

• • A clear description of the problem
• • Details of containment actions
• • Results of the root cause analysis
• • The corrective actions taken
• • Evidence that corrective actions worked
• • Preventative measures

Best practices for writing the report:

• Use clear, concise language.
• Use data to justify your conclusions.
• Use visuals when they clarify the point.
• Keep the report updated as you move through the 8D process.

Why document each step? It creates a paper trail of your problem-solving process, supports decision making, and allows other people in your company to learn from what you’ve already tried.

Use 8D reports to update stakeholders on your progress (both during and at the end of the 8D process). Keeping stakeholders informed aligns everyone involved in solving a problem. And a rule I live by is that the more aligned all stakeholders are, the more trust and support you’ll have in your problem-solving process.

Challenges and Best Practices in 8D Implementation

While implementing 8D is complex, the benefits justify the investment. Common challenges include change resistance, resource constraints, and difficulty determining the true root cause.

• To mitigate these challenges:
• Get management buy-in
• Offer proper training
• Allow time to conduct a thorough analysis
• Create a blameless culture that focuses on making things better
• Tips to ensure successful implementation of 8D:
• Start with small pilot projects to gain confidence
• Use a skilled facilitator to ensure early success
• Standardize your 8D process and tools
• Continuously assess and improve your 8D system

Measuring the effectiveness of your 8D process is essential. Use KPIs such as problem recurrence, time to solve, and customer satisfaction.

In consulting, I’ve witnessed companies completely change their ability to solve problems accurately by implementing a robust 8D process. It’s not easy, but the quality improvements and cost savings are significant.

Parting Thoughts

The 8D problem solving process is a great framework for addressing complicated problems. It offers a systematic way to discover root causes and resolve them with permanent solutions. In my experience, the key to success is ensuring proper execution through commitment, training, and cross-functional teamwork.

You’ll encounter challenges, but the benefits of the 8D process justify the investment. By using the 9 step methodology and selecting the right tools, you can instill a culture of continuous improvement within your company. Just keep in mind that effective problem solving is a continuous journey. Continue to optimize your strategy, and you’ll notice a significant increase in both efficiency and quality.

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Article • 8 min read

8D Problem Solving Process

Solving major problems in a disciplined way.

Written by the Mind Tools Content Team

(Also known as Global 8D Problem Solving)

When your company runs into a major problem, you need to address it quickly. However, you also need to deal with it thoroughly and ensure that it doesn't recur – and this can take a lot of effort and elapsed time.

The 8D Problem Solving Process helps you do both of these seemingly-contradictory things, in a professional and controlled way. In this article, we'll look at the 8D Problem Solving Process, and we'll discuss how you can use it to help your team solve major problems.

Origins of the Tool

The Ford Motor Company® developed the 8D (8 Disciplines) Problem Solving Process, and published it in their 1987 manual, "Team Oriented Problem Solving (TOPS)." In the mid-90s, Ford added an additional discipline, D0: Plan. The process is now Ford's global standard, and is called Global 8D.

Ford created the 8D Process to help teams deal with quality control and safety issues; develop customized, permanent solutions to problems; and prevent problems from recurring. Although the 8D Process was initially applied in the manufacturing, engineering, and aerospace industries, it's useful and relevant in any industry.

The eight disciplines are shown in figure 1, below:

Figure 1: The 8D Problem Solving Process

The 8D Process works best in teams tasked with solving a complex problem with identifiable symptoms. However, you can also use this process on an individual level, as well.

Applying the Tool

To use the 8D Process, address each of the disciplines listed below, in order. Take care not to skip steps, even when time is limited; the process is only effective when you follow every step.

Discipline 0: Plan

Before you begin to assemble a team to address the problem, you need to plan your approach. This means thinking about who will be on the team, what your time frame is, and what resources you'll need to address the problem at hand.

Discipline 1: Build the Team

You should aim to put together a team that has the skills needed to solve the problem, and that has the time and energy to commit to the problem solving process.

Keep in mind that a diverse team is more likely to find a creative solution than a team of people with the same outlook (although if outlooks are too diverse, people can spend so much time disagreeing that nothing gets done).

Create a team charter that outlines the team's goal and identifies each person's role. Then, do what you can to build trust and get everyone involved in the process that's about to happen.

If your team is made up of professionals who haven't worked together before, consider beginning with team-building activities to ensure that everyone is comfortable working with one another.

Discipline 2: Describe the Problem

Once your team has settled in, describe the problem in detail. Specify the who, what, when, where, why, how, and how many; and use techniques like CATWOE and the Problem-Definition Process to ensure that you're focusing on the right problem.

Start by doing a Risk Analysis – if the problem is causing serious risks, for example, to people's health or life, then you need to take appropriate action. (This may include stopping people using a product or process until the problem is resolved.)

If the problem is with a process, use a Flow Chart , Swim Lane Diagram , or Storyboard to map each step out; these tools will help your team members understand how the process works, and, later on, think about how they can best fix it.

Discovering the root cause of the problem comes later in the process, so don't spend time on this here. Right now, your goal is to look at what's going wrong and to make sure that your team understands the full extent of the problem.

Discipline 3: Implement a Temporary Fix

Once your team understands the problem, come up with a temporary fix. This is particularly important if the problem is affecting customers, reducing product quality, or slowing down work processes.

Harness the knowledge of everyone on the team. To ensure that each person's ideas are heard, consider using brainstorming techniques such as Round Robin Brainstorming or Crawford's Slip Writing Method , alongside more traditional team problem solving discussions.

Once the group has identified possible temporary fixes, address issues such as cost, implementation time, and relevancy. The short-term solution should be quick, easy to implement, and worth the effort.

Discipline 4: Identify and Eliminate the Root Cause

Once your temporary fix is in place, it's time to discover the root cause of the problem.

Conduct a Cause and Effect Analysis to identify the likely causes of the problem. This tool is useful because it helps you uncover many possible causes, and it can highlight other problems that you might not have been aware of. Next, apply Root Cause Analysis to find the root causes of the problems you've identified.

Once you identify the source of the problem, develop several permanent solutions to it.

If your team members are having trouble coming up with viable permanent solutions, use the Straw Man Concept to generate prototype solutions that you can then discuss, tear apart, and rebuild into stronger solutions.

Discipline 5: Verify the Solution

Once your team agrees on a permanent solution, make sure that you test it thoroughly before you fully implement it, in the next step.

• Conducting a Failure Mode and Effects Analysis (FMEA) to spot any potential problems.
• Using Impact Analysis to make sure that there will be no unexpected future consequences.
• Using Six Thinking Hats to examine the fix from several different emotional perspectives.

Last, conduct a Blind Spot Analysis to confirm that you and your team haven't overlooked a key factor, or made an incorrect assumption about this solution.

Discipline 6: Implement a Permanent Solution

Once your team reaches a consensus on the solution, roll your fix out. Monitor this new solution closely for an appropriate period of time to make sure that it's working correctly, and ensure that there are no unexpected side effects.

Discipline 7: Prevent the Problem From Recurring

When you're sure that the permanent solution has solved the problem, gather your team together again to identify how you'll prevent the problem from recurring in the future.

You might need to update your organization's standards, policies, procedures, or training manual to reflect the new fix. You'll likely also need to train others on the new process or standard. Finally, you'll need to consider whether to change your management practices or procedures to prevent a recurrence.

Discipline 8: Celebrate Team Success

The last step in the process is to celebrate and reward your team's success . Say "thank you" to everyone involved, and be specific about how each person's hard work has made a difference. If appropriate, plan a party or celebration to communicate your appreciation.

Before the team disbands, conduct a Post-Implementation Review to analyze whether your solution is working as you thought, and to improve the way that you solve problems in the future.

In the late 1980s, Ford Motor Company developed the 8D (8 Disciplines) Problem Solving Process to help manufacturing and engineering teams diagnose, treat, and eliminate quality problems. However, teams in any industry can use this problem solving process.

The eight disciplines are:

• Build the Team.
• Describe the Problem.
• Implement a Temporary Fix.
• Identify and Eliminate the Root Cause.
• Verify the Solution.
• Implement a Permanent Solution.
• Prevent the Problem From Recurring.
• Celebrate Team Success.

The 8D Problem Solving Process is best used with a team solving complex problems; however, individuals can also use it to solve problems on their own.

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8D Problem Solving / 8 Disciplines

Published by Jeff Hajek on May 13, 2009 May 13, 2009

The 8D problem solving methodology is similar to the DMAIC approach utilized by Six Sigma. Of note, 8D is a shortened form of the original name, ‘8 Disciplines’.

The 8D’s are:

• Identify the problem
• Use a team approach/form an 8D team
• Describe the problem
• Interim containment
• Define the root cause(s)
• Develop solution(s)
• Implement the solution(s)
• Prevent recurrence
• Congratulate the team

This 8D definition may raise the eyebrows of those familiar with the DMAIC problem solving methodology from Six Sigma. Many of these problem solving steps do, in fact, overlap with the DMAIC process. ‘Describe’ the problem (in 8D) aligns with ‘Define’ in the DMAIC methodology. ‘Define the root’ causes is similar to the ‘Analyze’ step, etc. Problem identification and congratulating the team in the 8D steps are not directly stated in the DMAIC methodology, but rather are implied.

The single biggest difference in the two methods seems to be the specific mention of ‘Interim Containment’ in the 8D methodology. This is the process of building a temporary stopgap into the process. While it is generally also done in conjunction with other problem-solving methods, formally mentioning it in 8D helps prevent skipping the step.

So, which is better DMAIC or 8D Problem Solving? Both are strong methods for solving continuous improvement problems. Both provide a consistent , structured approach, and both provide a common language so project status can be easily communicated throughout an organization.

My recommendation is to try both, and then choose the one that works best for you and your personal style. I would encourage you to establish (or follow, if it already exists) a corporate standard so the entire organization is using the same approach. That helps prevent confusion. And don’t be shy about altering the process steps to suit your needs.

The key point is to find a method that works for you, and then to use it.

Warnings about 8D Problem Solving:

• No matter how good a problem-solving methodology is, it will only work if it is used.
• Teams will not get good at problem-solving unless they are allowed to actually do it. During the learning process they will make mistakes. Managers need to be ready for this and use the errors as teaching points.
• The 8D problem solving process is one of many methodologies. Your company will work most effectively if you pick one and stick with it. It can be confusing to have different factions within your organization using different tools.

One of the most valuable skills you can develop is the ability to effectively solve problems. Because most people take a haphazard approach to coming up with solutions, the simple fact that you know about a step-by-step problem-solving methodology such as the 8 disciplines gives you a significant boost in the eyes of your leadership team.

The challenge most people have, though, with developing problem-solving skills is that the path is paved with mistakes. You don’t get good at solving problems without practice. And when you first start practicing, there will be a learning curve.

A good way to mitigate this is to find a mentor. He or she can help you avoid critical mistakes. A strong mentor shouldn’t insulate you from obstacles, though. Part of the learning process is figuring out how to deal with pitfalls. A good mentor knows how much leeway to give you while you attempt to overcome these challenges on your own.

Communication is also important. When you stretch yourself as you learn the 8D process, keep your boss in the loop. That way when you make mistakes, it will not be a big surprise for her. Good bosses recognize that teaching team members is an investment. A few mistakes now in a controlled environment is a small price to pay for turning you into a skilled problem solver for the future.

One of the best investments a leader can make in his or her team is developing problem-solving skills. Simply teaching the eight disciplines will make a marked improvement in your team’s ability to deal with issues quickly, efficiently, and effectively.

Bear in mind that there will be bumps along the way. Your team will make mistakes. How you deal with those mistakes will go a long way towards determining how committed they will be in taking on the challenge of learning to be effective problem solvers.

If they feel like they will be at risk when they take a chance, they will be tentative and reluctant to try. On the other hand, if they see that you will be reasonable and forgiving if they went through the problem-solving process, they will be more likely to internalize the methods.

The key is communication. You have to stay in touch with your subordinates who are working outside of their comfort zone. Ask a lot of questions and pay attention when your “Spider Sense” starts to tingle. For example, if a team member can’t clearly articulate what the problem is, pay attention to your gut. Don’t let them move on and start spending resources until they can convince you that they thoroughly understand the issue. Use a combination of scheduled meetings and ad hoc coordination as part of your communication plan. This keeps rookies from getting too far into the 8D process without you checking on them.

Try out each of the problem-solving methods on the same problem, at the same time. You might try having two teams both tackle the same problem in something of a competition of the methodologies.

This will let you get a true comparison of the two problem solving processes on an even footing. It is some extra up-front work but will help you make an informed decision about what works best in your company.

Click ‘Continue Reading’ to answer a poll question about using 8D Problem Solving.

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8D Problem Solving: Comprehensive Breakdown and Practical Applications

The 8D problem-solving process stands as a beacon of structured analysis and corrective action within the complexities of operational pitfalls and quality control discrepancies across industries. Originating from the automotive industry and since adopted widely, the methodology offers a meticulous step-by-step approach that fosters team cohesion, addresses problems at their roots, and implements sustainable solutions.

This article seeks to delve into the nuances of the 8D problem-solving framework, presenting a lucid exposition of its origins, a detailed foray into each step enriched by practical examples, and concluding with the unequivocal benefit bouquet it presents to the organization adopting it.

The Origins of the 8D Problem Solving Methodology

The 8D, or "Eight Disciplines," problem-solving approach germinated from the fertile grounds of collaborative efforts to ensure superior quality and reliability in manufacturing. Initially developed by the Ford Motor Company in the 1980s, this systematic method was a response to a confluence of quality and operational issues that were pervasive in the automotive industry. It drew broader appeal as its efficacy became apparent - functioning as an amalgam of logic, analytics, and teamwork to tackle problems methodically.

The wide reach of the 8D methodology is evident in industries ranging from manufacturing to healthcare, aerospace to IT, and beyond. Its universal applicability stems from a foundational adherence to principle over process, transcending the intricacies of industry-specific challenges. By combining reactive and proactive measures, the 8D method helps in not just extinguishing the fire, but also preventing its outbreak, making it an enduring asset in the organizational toolkit.

The 8 Steps of Problem Solving

An incursion into the 8D methodology reveals a framework that is both systematic and flexible. Each step is sequenced to ensure that issues are not merely patched but genuinely resolved, implementing robust preventive measures to curtail recurrences. This section expounds on each disciplinary step and serves as a substrate for practical implementation examples, supplementing theoretical insights with real-world applicability.

Step 1: Establish a Team

The cornerstone of any formidable 8D approach begins with assembling a competent team. The wisdom embedded in this initial phase is the recognition that effective problem-solving is not a solitary venture but a collaborative pursuit. A multidisciplinary team brings diverse perspectives that are critical in diagnosing issues accurately and devising solutions effectively.

When determining team composition, the emphasis should be on a mix of skills and expertise relevant to the problem at hand. Roles within the team should be clearly defined to streamline activities and foster accountability. Each member should be well-versed in their responsibilities, from those leading the problem-solving charge to those executing and tracking actions.

Step 2: Describe the Problem

Clarity is vital in the second step, which necessitates delineating the problem with precision. A meticulous description sets the foundation for targeted analysis and actionable solutions. It involves accruing information that is factual, quantifiable, and devoid of assumptions – the cornerstone of an accurate problem portrayal.

Techniques like '5W2H' (who, what, when, where, why, how, how much) can galvanize teams into crafting detailed problem descriptions. An exemplar of a well-articulated problem statement might state, "Machine X has experienced a 15% decline in output quality, resulting in a monthly loss of 200 units of product Y since January due to recurrent mechanical inaccuracies."

Step 3: Develop Interim Containment Actions

Addressing a problem's immediate impact is pivotal to prevent exacerbation as a root cause analysis is conducted. Interim containment actions can be likened to first aid – essential, though not the definitive cure. These measures should be rigorously designed to quell the problem's spread or intensification without creating new issues.

An interim action for the aforementioned issue with Machine X could involve adjusting the production schedule to mitigate output loss while the machine is under examination. This demonstrates a temperate solution, buying time for a comprehensive fix without severely disrupting the production chain.

Step 4: Define and Verify the Root Cause(s)

Singular in its focus yet pluralistic in its approach, this phase is committed to uncovering the underlying reasons for the problem. Root cause identification is a task of surgical precision, necessitating a deep dive into the problem without the constraints of predetermined notions.

Techniques such as the "5 Whys" and "Fishbone Diagram" guide problem solvers through a structured investigation of potential causes. Verification is as crucial as identification, ensuring that purported root causes stand up to scrutiny and testing.

Step 5: Verify Permanent Corrective Action(s)

Once root causes have been established, attention shifts to devising and validating long-term corrective actions. This step traverses the path from theory to practice. It requires a judicious appraisal of potential solutions with a clear-eyed view of their feasibility, effectiveness, and sustainability.

Best practices in this step incorporate piloting solutions on a smaller scale, enabling refinement before full-scale implementation. A well-considered corrective action for Machine X might involve upgrading mechanical components identified as failure points, subject to cost-benefit analysis and potential disruption to the production line.

Step 6: Implementing and Validating Permanent Corrective Actions

This step transitions the plan into reality, pushing the corrective actions beyond the threshold into the operational environment. Careful implementation is the linchpin, with detailed plans and schedules ensuring that actions are well-executed and efficacious.

The validation process is a keystone in affirming that corrective actions deliver the intended improvements. For Machine X, this could entail monitoring post-repair performance metrics over a defined period against pre-issue levels to authenticate the efficacy of the improvements.

Step 7: Preventive Measures

Armed with insights gleaned, the 7th step propels the methodology into preventative mode. Here, the onus is on forestalling a problem’s resurgence by ingraining the lessons learned into the organizational fabric. The aim is to encapsulate these insights in policies, procedures, or system changes.

This could mean revising maintenance schedules or worker training programs for Machine X to include the specific nuances that led to the mechanical inaccuracies, thereby shielding against repeat episodes.

Step 8: Congratulate Your Team

The final step encompasses a human-centered focus on recognition and commendation. Acknowledgment of the team’s efforts reinforces motivation, fosters a positive culture, and encourages engagement in future problem-solving initiatives.

Celebrating the success could manifest in a ceremonious recognition of the team’s achievements, an internal announcement of their contributions, or a tangible expression of appreciation. This not only cements the accomplishment but also propels a sense of camaraderie and collective purpose.

The Importance of the 8D Problem Solving Process

A mature consideration of the 8D problem-solving process corroborates its contributory significance in unraveling complex issues and instituting consequential improvements. The benefits it confers are manifest in enhanced product quality, heightened customer satisfaction, and the stimulation of a proactive problem-solving culture. Challenges do persist, mainly in the form of resistance to change or insufficient training; nevertheless, with a conscientious implementation, these can be navigated.

Moreover, the 8D approach aligns seamlessly with the pursuit of continuous improvement – a cornerstone of many business philosophies such as Lean and Six Sigma. It thus serves not only as a solution framework but also as a catalyst for organizational growth and learning.

In summary, the 8D problem-solving methodology stands out for its disciplined, team-driven, and methodical approach to tackling complex problems. From its historical roots in the automotive industry to its implementation in modern enterprises, its efficacy in achieving sustainable solutions is undoubted. Online certificate programs and problem-solving courses often feature 8D due to its relevance and value across industries.

As this article delineates each step, with practical applications and advice, the message is clear: mastery of 8D is not just for immediate problem resolution – it is a pathway to building a resilient and adaptive organization capable of facing the challenges of an ever-changing business landscape.

What are the key steps involved in the 8D Problem Solving process and how do they interact with each other?

Introduction to the 8d process.

The 8D Problem Solving process stands tall. It is a structured approach. Businesses use it widely. 8D tackles complex problems effectively. It drives teams towards lasting solutions. It also fosters quality and reliability. The "D" denotes eight disciplined steps. These steps guide teams. They identify, correct, and prevent issues.

8D Steps Explained

D1: establish the team.

Form a skilled team first. Diversity matters here. Each member brings insights. Their combined expertise is crucial. Team formation kicks off the process.

D2: Describe the Problem

Articulate the issue clearly. Use quantifiable data here. Understanding the scope matters. Have accurate problem statements ready. They pave the way forward.

D3: Develop Interim Containment Action

Ensure a temporary fix. It limits the problem's impact. Speed is of the essence. However, ensure the action is effective. The goal is to stabilize the situation.

D4: Determine Root Cause

Dig deep into causes. Use data-driven analysis. Techniques include fishbone diagrams. Five Whys is also popular. Root cause analysis is pivotal. It prepares the team for corrective actions.

D5: Design and Verify Permanent Corrective Actions

Choose the best corrective action. Rigorous selection criteria apply. Effectiveness and efficiency matter. Verify through testing. Make certain the solution fits.

D6: Implement and Validate Permanent Corrective Actions

Roll out the solution. Watch closely for results. Validation takes place here. Use performance indicators for this. They must indicate that the solution works.

D7: Prevent Recurrence

Embed the improvement. Update systems and policies. Training may be necessary. Maintain the gains. This step safeguards the future. Documentation is important here.

D8: Congratulate the Team

Never overlook recognition. Acknowledge everyone's efforts. Celebrate the success achieved. It boosts team morale. It also promotes a culture of quality.

Interplay Between Steps

The interdependence is strong. Each step builds on the previous one. For example, a strong team in D1 enhances problem understanding in D2. Similarly, effective interim actions in D3 set the stage for a thorough root cause analysis in D4.

The verification in D5 ensures the solution from D4 is sound. Implementation in D6 then relies on the verified action. To prevent recurrence (D7), one must understand the root cause. The entire process relies on clear communication. Team recognition (D8) closes the loop neatly. It paves the way for future problem-solving success.

In essence, the 8D steps are interlinked. Each step informs the next. Teams achieve the best results by following the sequence. They also adapt as needed. 8D enforces a discipline that leads to high-quality results. The interaction between steps ensures problems do not just disappear. They stay solved. This is the power of an integrated problem-solving approach.

Can you provide some practical examples of the effective application of 8D Problem Solving strategies in real-life settings?

Understanding 8d problem solving.

8D problem solving stands for Eight Disciplines. It involves steps that teams must follow. Starting from identifying problems , it goes until preventing reoccurrences . Companies use 8D to tackle complex issues. Its main goal remains quality improvement.

Here are practical examples where 8D shines.

Example 1: Automotive Industry

D0: Plan - An auto manufacturer formed a team. Their goal was clear: resolve brake failures.

D1: Team Formation - They gathered experts from diverse fields. Collaboration was key here.

D2: Describe the Problem - They identified specific issues. Customers reported brakes failing at high speeds.

D3: Develop Interim Containment - They distributed quick-fix kits to dealerships. This ensured immediate customer safety.

D4: Determine Root Causes - A deep dive ensued. The team discovered a faulty brake fluid line.

D5: Choose and Verify Permanent Corrective Actions (PCAs) - They redesigned the brake line. Then they tested it under rigorous conditions.

D6: Implement and Validate PCAs - The new design went into production. Ongoing assessments confirmed its effectiveness.

D7: Take Preventive Measures - They updated their design guidelines. Thus, they eliminated the possibility of similar failures.

D8: Congratulate Your Team - Management recognized the team's effort. This promoted a culture of problem-solving.

Example 2: Electronics Manufacturer

D0: Plan - A sudden surge in returned gadgets prompted action.

D1: Team Formation - A cross-functional team took charge. They had one aim: find the flaw.

D2: Describe the Problem - Devices were overheating during usage. Anxiety among customers grew.

D3: Develop Interim Containment - They halted the production line. Assessing risks was necessary.

D4: Determine Root Causes - Detailed analysis revealed a substandard battery component.

D5: Choose and Verify PCAs - They sourced a higher quality component. Subsequent tests showed promising results.

D6: Implement and Validate PCAs - They integrated the new component into production. Monitoring phases ensured it was a fix.

D7: Take Preventive Measures - They revamped their quality control protocols. Now they could avoid similar issues.

D8: Congratulate Your Team - The team's innovative approach earned praise. They set new standards in their processes.

Example 3: Food Packaging Company

D0: Plan - Reports of packaging leaks triggered an 8D.

D1: Team Formation - Experts from production to distribution joined forces. They understood the stakes were high.

D2: Describe the Problem - The leaks were sporadic but damaging. Food safety concerns escalated.

D3: Develop Interim Containment - They removed compromised products from shelves. Protecting the consumer was paramount.

D4: Determine Root Causes - Investigation exposed a sealing machine defect.

D5: Choose and Verify PCAs - Engineers redesigned the sealing mechanism. Trials followed, proving success.

D6: Implement and Validate PCAs - The updated machines replaced the old ones. Continuous evaluations followed to assure quality.

D7: Take Preventive Measures - They introduced more rigorous maintenance routines. They aimed to preempt future failures.

D8: Congratulate Your Team - The swift and thorough response earned accolades. They reinforced trust in their brand.

8D's Practical Value

Each example showcases 8D's potential. This problem-solving framework adapts to various scenarios. Through structured teamwork and analysis, it guides toward sustainable solutions. It helps in ensuring the same problem does not occur twice. Businesses across different sectors find 8D crucial for their continuous improvement efforts. It underlines that a methodical approach to problem-solving can yield significant long-term benefits.

How is the effectiveness and success of the 8D Problem Solving approach measured in practical applications?

Introduction to 8d problem solving.

The 8D Problem Solving approach stands as a structured methodology. It aims to address and resolve critical issues within an organization. Rooted in the team-oriented approach, 8D follows eight disciplined steps. These steps ensure a comprehensive and effective resolution process. The process includes identifying the problem, implementing interim controls, defining root causes, developing a corrective action plan, taking corrective actions, validating those actions, preventing recurrence, and finally congratulating the team.

Measuring Effectiveness and Success

Quantitative metrics.

Timeliness of Response

The promptness of the initial response is critical. It alerts stakeholders to the emergence and acknowledgment of the issue.

Problem Recurrence Rates

A key success indicator is the frequency of problem recurrence. A declining trend signifies effective corrective actions.

Financial Impact

Cost savings or avoidance measures the fiscal efficiency of the resolution. It counts both direct and indirect factors.

Cycle Time Reduction

Improvements in processes can lead to shorter cycle times. This reflects efficiency gains from the 8D implementation.

Qualitative Metrics

Quality of Documentation

Comprehensive documentation ensures thorough issue analysis. It captures the nuances of the problem-solving journey.

Stakeholder Satisfaction

Feedback from affected parties gauges the outcome’s acceptability. Satisfaction levels can direct future interventions.

Knowledge Transfer

Disseminating learnings enhances organizational capability. Sharing insights leads to broader, preventive measures.

Team Cohesion and Growth

Personal and team development signal process benefits. Such growth provides intangible value to the organization.

Practical Application and Continuous Improvement

In practical applications, tailoring metrics to contexts is vital. Unique business environments demand specific success criteria. Therefore, adapting the approach and its measurement system is necessary.

Organizations may employ a combination of tangible and intangible metrics. Aligning these to strategic goals ensures relevance. The 8D Process receives fine-tuning through iterative cycles. Each cycle offers an opportunity for enhanced problem-solving efficacy.

The Importance of Measure Standardization

Standardizing the measurement process ensures consistency. It aids in comparing and benchmarking against best practices. Homogeneity in measures facilitates clearer communication. It enhances the understanding of successes and areas for improvement.

Revisiting and Refining the 8D Process

Upon completion, a rigorous review of the 8D process is crucial. It ensures learnings lead to process refinement. Alterations in measures might follow to better reflect evolving business needs. This ongoing evolution drives the sustained value of the 8D methodology.

The 8D Problem Solving approach, with its disciplined steps, delivers a robust framework. Measuring its effectiveness requires a blend of quantitative and qualitative metrics. These metrics, when standardized and continually refined, offer a clear lens to assess the 8D process's success. They help organizations not just to solve problems but to evolve in their problem-solving capabilities.

He is a content producer who specializes in blog content. He has a master's degree in business administration and he lives in the Netherlands.

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8D problem solving: how to diagnose & eliminate quality problems

Diagnosing and eliminating quality problems is at the heart of all Quality Management. There are several methodologies as to how to do this. One of the most widely implemented is 8D problem solving. This tried-and-true methodology gives teams a comprehensive and consistent way to address production problems, no matter where they are triggered along the production chain.

Several articles elaborate on why it’s important to diagnose and eliminate quality problems using the 8Ds. But how does this work if you’re using  quality management software ? Let’s find out

A quick intro to 8D problem solving

The Eight Disciplines of problem solving (8D) provides manufacturers with a team-oriented approach to addressing problems in the production cycle. It’s widely used throughout manufacturing and combines best practices from a variety of approaches to create a “best of all worlds” scenario. High-level goals folded into the 8D process include:

• Identifying the root cause of a problem
• Developing containment actions that protect customers

Organizations that employ 8D should experience systemic changes to their production process. They will also be able to improve and streamline the whole process. This helps them to eliminate the problem at hand but also reduce the occurrences of other problems down the line

So, what do the 8Ds stand for?

To achieve the high-level goals described above, a team should pursue these eight steps:

• Define the stakeholders addressing the problem.
• Develop a Problem Statement that correctly summarizes and defines the problem.
• Define and execute an interim containment action.
• Document the root cause of the non-conformance or non-detection, along with the                percentage at which it contributed to the problem.
• Define, select, and verify Corrective Action(s) needed to address the problem.
• Implement and validate the Corrective Action(s).
• Document all actions taken to prevent recurrence.
• Document and acknowledge the team contributions that led to the success of this                  process.

When to apply 8D problem solving

Typically, 8D is most applicable in the following scenarios:

• when safety or regulatory issues have come up in the production cycle
• if your company receives multiple and consistent customer complaints
• when warranty responses suggest product failure rates that are higher than expected
• in case internal factors such as waste, test failures, rejects or poor performance occur at  unacceptably high levels

Why apply 8D problem solving

Next to a collaborative and consistent way to address production problems, 8D also delivers other benefits including but not limited to:

• developing team-wide skills when it comes to solving production problems
• creating an ongoing record of failures that can inform problem solving efforts to come
• improved understanding of statistical tools leveraged in problem solving
• improved efficiency and effectiveness in team efforts to solve problems
• a better understanding of RCA (Root Cause Analysis)
• developing problem solving skills that can be adapted for other areas/departments in a          company
• enhanced skills when it comes to taking corrective actions
• enhanced collaboration and discussions around problem solving
• enhanced ability by the team to identify where change is needed
• improved management understanding of processes

How to leverage 8D if using quality management software

One of the most effective ways to leverage the 8D method is by applying it using a smart QMS. The cloud-based quality management system from AlisQI was designed to help manufacturers work smarter, not harder. We automate data collection, data analysis, project management and other routine tasks so that manufacturers can focus on continuous improvement.

Within AlisQI manufacturers have a QESH problem-solving page, a standardized dashboard based on the 8D methodology. Whether it’s a complaint, deviation or safety incident, this page provides all the components you need to analyze, follow up on and report production problems. It is available for all QESH processes, no matter their context.

A closer look at the Problem-solving page

The QESH problem-solving page is divided into four sections. Together, they make for an integrated approach to problem solving. To be more specific:

• Incident details This presents all information entered via the form to register or follow up on an incident. The form can be fully tailored. It details tasks leading up to the incident, the damage that occurred as well as immediate actions that have been taken.
• Attachments Uploaded images depicting the incident are shown right away. Other file types are linked and easily accessible. Teams can add just about any file type as an attachment. Typical examples include images, Word, Excel, PPT, or PDF files.
• CAPA actions Shows all connected corrective or preventive actions related to the incident, with their owner, due date, and status. The moment you assign an action, the action owner is informed automatically. The CAPA actions are managed centrally, so you always know who is doing what.
• Root cause analysis The lower right quadrant shows an example of five times why root cause analysis. This allows for a systematic approach to root cause findings.

Additionally, the smart QMS allows for the creation of full-featured 8D reports (including all actions and their status).

Do you want to learn more and actively use 8D problem solving to improve production? Book a free online demo, and we’ll show you how to set up effective QESH management so that you can focus on improving your business.

Otto de Graaf

Related articles.

8D (Eight Disciplines) – The problem Solving tool

In this modern era, to sustain products in the market needs to use advanced manufacturing processes. Modern machinery and cost effective processes for produce quality products with low cost. but as you all know that. It’s difficult to constant manufacturing processes and sustain product quality. Because it is natural that, during the working time unexpected problems can be occurred and that kind of problems must be resolved in respective manner. Some organizations are used outmoded technique that solve the issues on temporary basis. As well those problems can be possible reoccur in processes in future.

So, needs to efficient system that eliminate the possibility of reoccur issues as well as smooth the manufacturing processes. Fortunately, we have some problem solving tools can solve the issue permanently. 8D (Eight disciplines) is one of the popular problem solving tool that in now days, organizations are adopting pleasurably. OK, so let’s see how to implement 8D in organization.

What is 8D (Eight Disciplines)?

“8D (Eight Disciplines) is problem solving tool / methodology used for correctly identified the cause of the problem, fixed and dissipate possibility of recurrence of quality problems.”

8D model is systematic approach popularly used in responding to manufacturing issues. Generally, quality team conduct eight disciplines processes for identify root causes of problem and eliminate it by appropriate actions. The 8D (Eight Discipline) model is correctly identify the cause of the problem. And apply such actions to prevent recurrence of the problem. 8D is perform as preventive and corrective action system by implement step by step process to identify potential and actual problems in processes.

Benefits of 8D (Eight Disciplines)

• The 8D method is very easy for implement in workplace as well as logical method that clearly indicate required steps of problem solution.
• The method is very popular in automotive industry, mean your customer may ask for 8D report for its own application implementation. Because it is reliable and well know problem solving tool for automotive industry.
• An excellent way of reporting non conformance to suppliers and their corrective actions.
• 8D helps to eliminate complicated issues at appropriate locations where defined the causes of the problem incorrect, lack of consequences in implementation and same problem appear again.
• The team approach works best when the problem, and its associated information is labyrinthine. Because 8D is designed and capable for special cause of problems identification and elimination.

8D (Eight Disciplines) Process Chart: Table

8d (eight disciplines) methodology.

• D1: Team Establishment
• D2: Problem Description
• D3: Containment Action
• D4: Root cause
• D5: Corrective Action
• D6: Implement and validation corrective actions
• D7: Prevent recurrence
• D8: Verify and congratulate team

The 8D (eight Disciplines) is a process for systematic introduction of quality perfection, improvement and elimination of problems. Here in this article I will show you step by step approach and using several examples of the problem solving tools . When we involve in 8D methodology and its processes using a structured method, we become very effective at identifying cause of problems, defining problems and mistakes. As well as easily establish root causes and taking actions that solve and prevent problem identifying in processes.

So, let’s see 8D (Eight Disciplines) in deep:

As you well know, whenever any problem occurring in the manufacturing processes before you must see some warning sign that indicate the problem. Which is being experience in terms of an undesirable results and can be describe using data to identify the variation as expected and actual results.

Actually, this is the preparation stage that require to be complete before starting the eight disciplines processes in organization. Generally, peoples asking what type of preparation required before 8D process? –

A deep analysis and empathetic of the issues and problems, previous experience with same issues or related issues are necessary to determine. If the eight disciplines (8D) is the correct method to be used for solving the issues.

You have to ask the questions as below as recognizing the problem:

• Describe it is new problem in organization / division? If same problem, occur previously at where? If it is new how long from it were being in process. Or it is unknown cause?
• Has it occurred before? where? and what solutions / actions are applied at on it? What is the history of this problem?
• Why it’s happened again? is there proper solutions are not applied? what causes behind it is occur again?
• What problem solving method was used? It was joint method for one or more problem? if it is separately performed what was defects remained in method?
• To consider warning sign of problems is it really looks very complex to one person cannot resolve the problem?
• To consider above points, does the problem warrant required an eight Disciplines (8D) method? if yes, why and proceed it.

The 8D (eight disciplines) process is a team based problem solving methodology. Hence the team members must be involve for identify, action plan and eliminate issues of appropriate problem. A deeper understanding of the problem & its previous records are required to ensure if the 8D solved issues for raise issue.

D1 »  Team Establishment

The team establishment is first step of the 8D (Eight Disciplines) approach. This discipline is significant stage as the eight disciplines is based on the substance of team cooperation. Establishment group of peoples called CFT (Cross Functional Team) where must each one from different department is selected by management, with the production process knowledge, product knowledge, and skill in the required technical disciplines to solve the problem and implement corrective actions.

Why team approach is important?

• CFT (Cross Functional team) build by group of peoples from different department and expertise. So any technical issues can be possible to identify, fix and eliminate problem through it.
• A Cross functional team can perform more effectively than individuals trying to solve problems.
• Cross functional team may have adequate capability to introduce proper solution of the problem.
• A group of people can discuss, focus on negative effects of actions, and can think creatively.
• Brainstorming as a group can stimulate ideas giving the team a better perspective of the problem.

A Cross functional team for eight disciplines consists of more than two people who are closely concern to the problem. Generally, involves peoples form different departments in the organization coming together to solve a problem. The skills that the team members require for this discipline to ensure the proper solution are:

• (A). Team member must knowledge of product / part / item (manufacturing processes, assembly etc.)
• (B). Team member must know the process where the problem has showed itself.
• (C). Team member must have knowledge of the customer application, technical use and end application requirements.
• (D). Team member must have skill about decision making, communication skill , and analysis of the processes and data related to manufacturing processes.

How to define team role & responsibility?

Usually, every team must have leader, here the same team leader has an important role to establish procedures and implement actions accordingly. The team leader must prepare a list defining the team structure as eight disciplines concern. the list is also important to establish role & responsibility in 8D processes. Every team member has its own importance in 8D methodology. Because every single member comes with different expertise. Hence to solve problem multifunction conception and views helpful for appropriate issues.

The role and responsibilities of the individual team member must have allocate by the team and will involve some of the points are:

Data collection and analysis, experimentation, decision making processes, modelling managing resources, planning and implementation of action plans, action plan verification and validation, communications etc.

The common processes and requirements for the 8D processes needed to contribute to the problem solving effort.

D2 »  Problem Description

Problem description is a second stage designate for deep into the problem & getting a more complete information and sophisticated understanding of the problem. The problem description indicates, problem clearly identify and the eight discipline problem solving planner activities to take as much actual information as possible. Which organizes the first analysis perform in the problem solving process. You have to describe problem accurately in this stage, clear designed information is foundation to further steps of analysis.

The process of this discipline as below:

Describe The Problem Process Flow: Table

A problem description is the results of a practice that uses the is / is not method to magnify the problem statement. The location and nature of the problem have to be describe along with its impacts. Another very important analyzing results of information. To ensure that the problem involves is recurrent or whether it could occur on particular process or product.

See table below help for better understanding:

Describe the problem with Is / Is Not Method: Table

When the describing the problem with 5W + 2H (Who, What, Why, Where, When, how, how many / much) method should be use. Where you get the answered thoroughly and systematically by the questions.

See picture below for problem analysis worksheet:

Remember that, you have to specified problem statement been defined, and you have get to know for certain why that is occurring. So Is / Is not analysis must been perform for it. You have to also verify that the similar parts / components displayed the same problem? current process flow identified? does this process flow represent a change.

Once you get the answer you can collect the data and analyze it. The information you collected are evaluated for potential root causes, and identify physical evidence of the problem. The problem description been reviewed for completeness with 8D (Eight disciplines) customer and affected parties, and document the activities.

D3 »  Containment Action

This is the stage where are taken correct containment action to prevent escalation of the problem. Or at the worst delivering non-conforming product to the customer. You have to describe the containment action plan to put in place in order to eliminate the effects of the problem. In this stage, immediate correction action should be carrying out in the shortest time possible. The main objective of the implement interim actions / containment actions to isolate issues from parties while a permanent solution is being develop and implement.

Why containment action required?

• When the cross functional team working on identification of the root causes of problem , collecting information and other related processes might possible some defective product produced by manufacturing in tenure. So, it is extremely important containment actions on this condition at appropriate locations.
• To ensure the customer has minimal or no impact felt as a results of the problem identified, as well prevent these defective products from getting the customer.
• In case of any defective lot / product reached to customer, it may not comply requirements to end application, hence customer will claim and complaints as results customer dissatisfaction.
• Due to immediate actions, the similar products and processes must be verified and ensure the risk levels are minimum or not evident.

Through PDCA Cycle

Plan »  Prepare the most effective containment action plan and implementation including verifying the containment action effectiveness and concerned activities such as work instructions , resources and equipment available.

Do »  The plan must execute as containment action plan prepared, and ensure that the actions should be clearly communicated at processes and management levels.

Check » It is cross function team responsibility that every containment actions prepared during the planning section must be implemented exactly accordingly and ensure that it may continue to be effective. One of the important activity of this section is to verify and ensure that. The activities must not any other side effects raise as a result of the containment actions.

Act » Take the actions to ensure containment action are effective and sustained with all manufacturing and supporting processes. Take the questioners and get the feedback from internal and external customers to implement and make sure is there further containment actions or correction required to rectify other issues.

8D – Containment actions checklist

8D containment action points:

D4 »  root cause.

On this stage in Eight disciplines (8D) problem solving process, needs to establish and describing the root causes of a problem is the core of this disciplines. And you will have appraise the team structure and configuration to ensure that all the right skills and experience is available for the upcoming phases or processes in the problem solving effort.

Elimination of the problem should be detecting the real cause of the problem. The objective of the explain and verify root causes is to identify all significant causes which could clarify why this problem happens. An eliminate and confirm the root cause by examine each significant cause against the describe problem and results of tested data.

For define and verify root causes you have to step out as below:

• Establish a process flow and Cause and Effect Diagram to include all the sources of variations.
• Develop a stratification cause and effect diagram, but remember that, the cause and effect diagrams used input from all team members, lack of the information of remains any points or data left, you will not get real cause.
• Establish comparative analysis, by determine critical differences between problem location and non-problem locations.
• You can also use time line analysis. Graphical / visual charts give you better understanding in most cases.
• Index the potential causes of problems by use both the process flow and cause and effect diagram.
• By using the both the tool, you can analyze the potential cause for the most likely cause.
• Determine slot of data, identify the potential cause as a root cause.
• Collect and analyze the appropriate information to identify the potential cause as a root cause.
• Specify causes that permitted the apparent warning sign to occur, are the root causes and often repressed deep in the processes. You can use the tools to help in the whole processes that is problem solving techniques are : (1)  Pareto charts  (2) 5 Whys analysis (3) Statistical analysis (4)  Flow charts  (5) Fishbone diagram (6) GR & R study (7)  FMEA  (8) Frequent audits (9) Fault tree Analysis (10) Brainstorming etc..

The time line is one of the important and useful tool that manage the records at time line of all events in and around the problem.

A company making steel tubes is experiencing a pits on tubes problem identified.

The significant processes / event are recorded on a time line are:

The time line helps to draw processes and events on time. Though it you can get the answer when actually the problem was first seen at which location. Now you can filter out possible causal theories later in the process by identifying what could possibly have caused the problem and what could not have caused the problem.

There are more three important stages you have to concentrate are:

(1) Develop possible causal theories (2) Establish possible root causes (3) Verify possible root causes and define and verify escape point.

You must do deeply thought about the possible causes and documents on separate media. For each of the cause you have to prepare a proper theory that describe how that the possible cause would result in the problem being experienced. You have to do write note of each ideas for develop causal theory for possible root causes.

Ask the simple question to each causal points that answered in “IS” / “IS NOT”. Does this explain the reason why the problem exists on the “IS” and not on the “IS NOT”. For separately of the possible root causes, there now requirements to be useful action to validate the possible root cause. This should be carried out in practical terms wherever possible.

D5 »  Corrective Action

On the fifth stage of eight disciplines, the cross functional team must determine which corrective actions should be establishing and implement in the short period of time to ensure that the processes and product quality maintained and controlled. The corrective actions must be requirements that satisfy both the parties internal and external customers. Once the root causes are known, team concentrate on the permanent solutions, by systematic approach is needed to use the root cause analysis to establish actions for proper solution. The points that you need to focused on:

• Empathetic and defining the problem, the eight disciplines (8D) team must be able to defining the problems and implement the solution practically.
• Enclosing the effects of the problem, please note that implementation and using the program for solution must be cost effective.
• Identifying and verifying the root cause of the problem.
• Need to permanently solve the problem, and the solution must be feasible.
• Confirm the potential solutions through testing programs, and remember that the implementation program should not fail during the implement in production so, it is important the solution is a test and essential characteristic such as mistake proof and affordable.
• Verify that the solution eliminates the problem and its effects;

In fifth stage of eight disciplines, the team can introduce the additional control in the processes, and ensure that the solution is properly validated that during the implementation in running production it will not raise any unwanted issues, so trail on the small quantities first to verify the solution is effective is necessary. To ensure that the permanent corrective actions need to establish proper process flow for it, see the example process flow:

Verify Corrective Actions Process Flow: Table

Verify the corrective actions.

It is extremely important that all the established actions and implementation plans for fix the issues must be performed to not leading any further problems. So, cross functional team must well aware of this kind of technicality and must should try out the implementation program with small part of production or small quantities first to verify its effectiveness.

Corrective actions test with pre-production with small quantity can confirm that the identified corrective actions will resolve the problem of the customer, and ensure that will do not any undesirable side effects.

Check points

Somethings that still need to confirm and ensure that corrective action is will properly works at real production. Some points that help you to re-verify the condition such as:

• (1) List and measure all of the indicators related to the program.
• (2) identify which of the indicators are most direct relation to the program.
• (3) Determine intervals to measure the problem.
• (4) identify what cross fictional team prioritized the customer / end user evaluation after the implementation.
• (5) confirm the scientific methods used to verify effectiveness etc.

D6 »  Implement and validation corrective actions

On the stage of validation corrective actions, the cross functional team consists of measuring the long term effectiveness of the corrective actions. The purpose of verification of the corrective action is ensure that the actions are implemented are efficient and these are eliminated permanently through effective controls and activities that are embedded in the tasks of the process. Some indicators that you can ensure that the corrective actions are properly works:

• Test and control results display improvement
• Less Rejection or reject ppm (%) in process.
• Measurements such as dimension, units’ appearance are correct according to tolerance and specifications.
• Controls on incoming raw materials for quality improvement.
• Increased satisfaction ratio and feedbacks from customers.

The statistical tools such as process capability, histograms, control charts etc. can used to measured and verify the effectiveness of the implemented corrective actions. The cross functional team must have informed to customer about the results achieved, if the process capability submitted with the requirements the customer validates the corrective measures functional. The 8D team confirms whether the capability complies with internal manufacturing requirements, if the process capability complied the team validates the corrective action.

Checkpoints:

You can use PDCA cycle for implement this stage in manufacturing processes. The implementation of the permanent corrective action conduct to implement to verify the plan for validation of the corrective action. You can plan to withdraw containment (immediate) action as part of implementation of the corrective actions.

There is also important that each resources used in processes must be properly planned as well as all documentation, process instructions and communication implementation for corrective actions. Check that the corrective actions have been implemented and integrated into the appropriate tasks and manufacturing processes. Take the actions on any variation from the plan or expected results.

D7 »  Prevent recurrence

On this stage, the cross functional team have to determine what action should be taken to prevent recurrence of the problem. You have to amend those operating systems, regular practices, management system as well as procedures to prevent recurrence of this problem and all similar issues. Because preventing recurrence is a one of the important task of problem’s solution. The general process flow of the prevent recurrent is:

• Input implemented corrective actions and validation
• Review the history / previous record of the problem.
• Analyze how this problem occurred and escaped.
• Identify affected parties and opportunities for similar problems to occur and escape
• Identify the system’s policies, practices and procedures that allowed this problem to occur and escape to the customer.
• Revise the process flow of the management or operating system.
• Analyze how similar problems could be addressed.
• Develop plans to coordinate necessary actions. And verify prevent actions.
• Develop systematic prevent recommendations to process owner.
• Identify and choose prevent actions. And implement preventive actions.
• Make the system changes to prevent recurrence.
• Verify the preventive actions are effectives? If yes, Standardize the new practices.
• Notify all personnel of the resolution actions by using failure mode effects analysis.

In this stage of the 8D (eight disciplines) cross functional team analyses whether the corrective action implemented would prevent or improve the quality of similar products and processes. To ensure the prevent recurrent of the problem, you should verify results of their actions and must validate that the results is on target. To verify the actions, you must check out below points:

D8 »  Verify and congratulate team

The last stage of the 8D (Eight Disciplines) Is verification of the introduced actions in previous stages are effective. It is highly recommended that verification be made by comparing the measures of the problem with outcomes from upcoming actions of material or outcomes from rejecting of next lot. Once cross functional team has complete implementation all previous stages and ensure that the actions taken in previous stages are works. All team member deserve to be congratulate as well to know that their efforts are appreciate and that the organization knows about their accomplishments.

The cross functional team must have skills and experience to be able to make progress toward as satisfactory problem resolution, and skills and experiences are base reasons for individual selection. Different skills and experiences will support to be drafted in at various stages throughout the process to get the deep understanding about the symptom of problem, root causes and resolution.

The 8D report

From beginning to end of all 8D (Eight Disciplines) processes, the single document calls 8D report is essential part once complete. Team assume that all things are complete and fix as appropriate actions for appropriate issues. This report serves as a communication tool displaying overall process of the 8D (Eight Disciplines) processes along with actions taken. So, let’s see example format of 8D report:

Conclusion:

When the problem has been resolve. The cross functional team should release a final document with stage wise brief description about its experiences. The 8D report give quick and better explanation of how the whole process had handling by team and also 8D serves report as a communication tool displaying overall progress of process.

We can assume that, the successful corrective actions have eliminated repetition of problems and prevention of similar issues. Further, team must ensure that corrective actions will be assess on their ability to help avoiding future problems. If we do not distinguish between major and minor problems, any issue will hold the delivery of customer and that is the reason we must have to categorize by identify systematic issues to eliminate appropriate problems.

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No Problem at All: Diagnosing the 8 Disciplines of Problem Solving

When problems appear, discipline is vital. Disciplines also help, and the eight disciplines of problem-solving (also referred to as the 8Ds) offer a proven process improvement structure that provides a framework for identifying root causes, eliminating them, and preventing reoccurrence.

The enduring popularity of the 8Ds attests to their power. It’s a tried and tested format on which you can rely — no matter what has gone wrong elsewhere.

How the 8 Disciplines of Problem Solving Evolved

In the 1980s, the Ford Motor Company published its manual, Team Oriented Problem Solving   (TOPS), the first articulation of the 8Ds. Eventually, it refined the original procedures into the current 8Ds.

Ford also added an initial planning stage (D0). There are now nine steps of 8D. Fortunately, the actual process is more intuitive than its numbering.

Initially developed for the auto industry, the 8D problem-solving process has been successfully adopted across multiple industries, including healthcare, government, finance, retail, and manufacturing.

How 8D Can Help You

The benefits of 8D  include:

• More effective and efficient problem solving
• A team-oriented approach
• Open communication within the team and with management
• A framework for corrective action that allows for systemic changes and continual improvement
• Intense examination of the control systems that permitted the problem
• Easy integration with process-improvement tools

You can apply the 8Ds whenever processes break down. Engineers and manufacturers often turn to them when they receive customer complaints or discover safety or regulatory issues. They also come in handy when a system’s amount of waste or a product’s failure rates hit problematic levels.

What Are the 8 Disciplines of Problem Solving?

The 8Ds provide a methodical approach to problem-solving. The sequence of nine steps will take you from the initial discovery of an issue to your celebratory toast when you fix it.

The designers added a planning stage to the original 8D methodology. This stage focuses on the one following, bringing clarity and intention to the project.

Summarize the Issue

You’ll describe it in greater detail later, but you’ve started this process because you identified a problem. What is it?

Collect the information on the problem’s symptoms and identify apparent gaps or additional needs. You might also want to consult a subject matter expert and get their input on your issue. They may be able to save you time further down the road.

Identify and Take Emergency Responses

If your house is on fire, put it out. Then you can take a hard look at the wiring.

As soon as you’ve identified a problem, take any necessary action to limit or contain a dangerous situation. Don’t overreact or prematurely make uncertain changes. Just exercise common sense.

Plan for the 8Ds

Your actual project plan will change as you make discoveries. This document is simply an outline of the project’s space within your company. It’s a theory about the necessary investment of time and other scarce resources.

Identify the resources you have and need. Sketch out schedules and note the variables that will affect them.

D1: Form Your Team

Create a team to tackle the problem.

Add the Right People

The group should be small enough to be efficient but large enough to cover all necessary process/product knowledge and technical skills. Some recommend a team of about five members. Make sure this team has the necessary authority and allotted time they need.

Identify both a team leader and a project champion in management (if necessary). Establish guidelines for harmonious group work.

This is also the time to perform team-building exercises if you want.

Review the Problem

Get team members up to date and fully on board. Review the initial brief for the project and discuss scope and priorities. Team members should all have the opportunity to voice initial concerns and complications.

D2: Define and Describe the Problem

Outline the problem in as much detail as possible, using quantifiable terms. Clarify both what the problem  is  and  is not . The latter will help you begin eliminating potential reasons for failure.

As you define the problem, you should also understand whether your situation is “something changed” or “never been there.” Has something gone off course, or has a new variable or context appeared?

Identify Critical Process Steps

Create a flowchart for the flawed process, and indicate which steps are critical to the problem at hand. In this step, you will start to approach root cause analysis, though you won’t isolate and verify a root cause until D4.

Outline Project Plan

At this point, you will develop a more detailed, high-level project plan that includes milestones, objectives, and a fuller schedule.

D3: Contain the Problem

D3 focuses on  interim  containment action rather than permanent and preventive action.

This step isn’t about emergency action, which should have been taken already. You’ve put out the house fire, but you still need to lodge your tenants elsewhere while your electricians go through the place.

Find a Temporary Solution

Take whatever action is necessary for the satisfaction of your customers or the effectiveness of your organization. You may need to develop workarounds, issue (non-emergent) recalls, or establish a resource for affected customers.

The ideal interim solution is:

• Inexpensive
• Simple and quick to implement
• Easy to reverse
• Validated by customer or employee feedback

When you’ve realized your long-term solution, you can do away with interim measures.

D4: Find the Root Cause

Root cause analysis is at the heart of most problem-solving tools and processes. It’s time to dig deep into the problem and find out what’s gumming up the works.

Develop Root Cause Theories

You’ll complete the process of elimination that you began when defining the problem. Refer to your flowchart. What could be causing the problem?

Use root cause analysis tools like the Fishbone Diagram  and the five whys . Find all possible factors that could contribute to the breakdown.

Test and Review Causes

Test each of your potential causes, collecting data until you can rule out all but one.

Identify Escape Point

In addition to finding the root cause, you need to figure out what part of the control system allowed it to escape detection and be contained. Find the point where someone or something should have caught the issue. That’s the escape point.

Correctly identifying and solving escape-point issues is essential to preventing future problems.

D5: Identify and Test Solutions

You’ve found the problem and its escape point. Of course, that’s only half the battle. Now you need to solve them — permanently and completely.

Define what “solved” looks like. Is there a threshold of minimum acceptability?

Develop Solutions

Give your team the time to consider potential approaches to both the root cause and escape point issues. The first idea may not be the best, and brainstorming tools such as affinity diagrams  can help.

Test Solutions

Make sure they work. You should also perform risk and cost analysis for any final contenders.

D6: Choose Solutions and Put Them Into Practice

Choose your best solutions, outline your implementation plan, and move forward with it. Both management and team members should sign off on the solution.

Implement, Validate, Monitor

After putting your plan into practice, check with customers and stakeholders to ensure that their concerns are fully addressed. Continue to monitor the situation to make sure the solution is sustainable and effective. You’ll also keep an eye out for any unintended consequences.

Move From the Interim to the Permanent Solution

Once you have the permanent solution up and running, you can end interim measures.

D7: Prevent Recurrence

By addressing the escape point and continuing to monitor the situation, you’re doing a fair amount to prevent an  exact  recurrence. But make sure that all contributing systems have been updated to reflect new input.

You should also preserve all documentation so that future teams have it as a resource for similar problems. Even better, prevent those similar problems.

Improve and Standardize Systems Across the Organization

Are there analogous areas of the organization that could use review? Are their policies and procedures in line with those you’ve developed?

Conduct an audit of operational procedures, management processes, and training manuals.

D8: Celebrate and Recognize Contributions

You’re not done quite yet. Recognition and validation are vital for a healthy organization, so take time to acknowledge individual contributions and the team’s accomplishments.

Perform a Final Review

Look at team output with a focus on before-and-after results. Finalize documentation and add it to the company library.

You should also take the time to reflect on your 8D experience. Explore trouble spots or areas that could use clarification for the next problem-solving team.

Reward your team appropriately. This can include anything from company-wide emails to dinner to bonuses. Even a personal email goes a long way toward making people feel like valued members of a community.

Then Do It All Again

When you make the eight disciplines of problem-solving part of your organizational DNA, you prepare to solve all kinds of problems in a streamlined, effective way.

The 8Ds integrate seamlessly with the Six Sigma methodology and make a great addition to your toolkit.

Discover your potential savings with our ROI Calculator

8D Management (8 Disciplines Management)

8D Management & The 8D of Problem Solving

Problems are a part of life and a business is no exception. Even with the best of intentions and systems, some errors can creep in and be hard to detect. It may be nothing serious or can have serious repercussions such as reputation damage, heavy fines, product recall, property loss, and so on. It becomes essential to identify the problem, its consequences on the one hand, and causes on the other to be able to not only resolve it for now but also ensure prevention of its recurrence. One of the methodologies, popular amongst engineers and professionals mainly in the automotive industry but now applied across several industries is the eight disciplines (8D) model. It helps to identify, correct, and eliminate recurring problems, affecting improvement in product and process.

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What is 8D?

The 8D is a systematic, holistic and proven methodology designed to identify the root cause of a problem, plan a quick fix, and implement corrective actions and preventive actions to avoid their recurrence. If your product is defective or not meeting your customer requirements, then 8D is an excellent first step to improve Quality and Reliability.

One of the core parts of introducing 8D problem solving , greatly accepted by most disciplines of industries, and having huge effectiveness levels in improving product and process quality, would be 8D (Eight Disciplines). Key steps in the 8D methodology are forming a team, defining the problem, identifying and implementing interim containment, identifying the root causes, implementing and verifying permanent corrective actions, and avoiding future recurrence of problems. The 8D process for root cause analysis concludes by highlighting that the team members not only play a vital role but also recognizes them, hence reinforcing that this approach is a collaborative one. 8D has become very popular among manufacturers, assembly, and services around the globe because it is effective and comparatively easy to teach.

Introduction to 8d Problem Solving

The 8D approach to problem solving , also known as the 8D methodology, is a systematic and comprehensive method used to address and resolve complex issues, particularly in manufacturing and other industries.

This 8D troubleshooting methodology involves a structured process designed to identify, correct, and prevent issues, ensuring that similar problems do not occur in the future.

By following the 8D process steps , teams can effectively perform root cause analysis and implement corrective actions.

The 8D structured problem-solving process is highly valued for its ability to provide a clear framework for identifying and eliminating the root cause of a problem, thereby enhancing overall operational efficiency.

Why to Apply 8D Problem Solving Methodology?

The 8D methodology , developed to represent the best practices in problem solving, provides the engineering teams with an effective and efficient team-oriented problem solving skill, a better understanding of Root Cause Analysis (RCA) and how to use basic statistical tools required for problem solving. 8D helps the management understand and resolve problems better, identify necessary systemic changes and inputs for change, and facilitate a more candid and open communication in problem solving discussions.

8D improves the Quality and Reliability of your products, and if performed correctly, prepares the engineering team for future problems.

When to Apply 8D Problem Solving Process?

The 8D problem solving process is used to solve major, critical, chronic, and recurring problems. The 8D is typically required during safety or regulatory issues, customer complaints , warranty concerns, poor performance or test failures, internal rejects, and to minimize waste and scrap.

How to Use Root Cause Analysis to Transform Your Safety Program

8d problem solving approach.

The 8D is a systematic process for the introduction and improvement of quality, and elimination of problems. Here we will show you the step by step approach of the 8D problem solving tools that can make you proficient at identifying causes of problems, defining problems, and errors. Additionally, it helps identify root causes and take actions to solve and prevent identified problems in processes. So, let’s take a peep inside:

D0: Planning and preparing for the 8D

Proper planning and preparation are always a good start before taking any action. So, you need to consider the following before forming a team:

• Problem description
• Timeframe for the resolution
• The number of resources to accomplish this

D1: Team establishment

Create a team with people who varied backgrounds and experiences which will lead to the best quality inputs and a complete solution. For the team to function smoothly, define clear roles, and responsibilities for your people, and have a team leader.

D2: Problem description

The 8D method’s primary focus is to describe the problem appropriately and objectively such that it captures all the vital information. During this analysis, repeated 5W1H (why, what, who, where, when, and how) are required to be asked to develop a clear description.

D3: Problem containment plan

A temporary problem containment plan is sometimes needed to minimize the impact of the problem until you develop permanent solutions. On developing the plan based on the hypothetical cases, the resources for addressing the main problem can be released. At times, new processes may be required to work around the problem until you have a permanent fix.

D4: Root Cause Analysis (RCA)

With the problem temporarily contained, you can now turn to identify all of the root causes of the nonconformance . There are several tools to identify the actual root cause of an issue including the 5W1H to understand the problem in-depth, Fishbone diagrams to visually categorize causes, and Pareto charts to identify the vital causes.

D5: Permanent Corrective Action

Once the root cause of the problem is determined, the team can start brainstorming permanent corrections to identify what the best long-term solution will be. Brainstorming sessions combined with tools such as affinity diagrams help organize ideas based on their relationships and determine the best course of action.

D6: Implement and Validate the Permanent Corrective Action

Once the solution is identified, the management needs to implement and verify the corrective action using the PDCA (plan-do-check-act) approach for small-scale testing before large-scale rollout. Thus, the outcomes and corrective actions are tracked to ensure expected results. To successfully implement a permanent change, a project plan should incorporate:

• Development of the project plan for implementation
• Communicating the plan to all stakeholders
• Validating improvements using measurement

D7: Prevent Recurrence

A complete solution of problems means preventing them from occurring. Besides, preventative measures should also be implemented for corrective actions in the 8D methodology. This requires reviewing management processes, operating procedures, and 8D training manuals to ensure that best practices are followed.

At this stage, organizations should consider actions including updating process audit questions and regularly verifying them based on corrective actions to reduce risk in other processes, presenting poka-yoke or error-proofing devices to big-risk processes, and conducting red rabbit tests to see how long it takes poka-yoke devices to detect defective product.

D8: Verification and Team Celebration

Once the problem is solved, the ultimate step is to congratulate the team. It’s important to recognize their efforts and share their success across the organization because teams require feedback to allow for satisfactory closure. This facilitates motivation and employee engagement while helping you improve quality control, execute process improvements, and aid change management as you grow.

Create a team with people who are having varied backgrounds and experiences which will lead to the best quality inputs and a complete solution. For the team to function smoothly, define clear roles, and responsibilities for your people, and have a team leader.

A complete solution of problems means preventing them from occurring initially. Besides, preventative measures should also be implemented for corrective actions in the 8D methodology. This requires reviewing management processes, operating procedures, and training manuals to ensure that best practices are followed.

8D Root Cause Analysis (RCA) and 8D Corrective Action Process

The 8D Root Cause Analysis, as well as the 8D Corrective Action process, is a widely systematic approach in quality management , especially concerning 8D in quality control. This method includes eight comprehensive steps that are devised to problem solving by dealing with root causes of the problems comprehensively. The steps of the 8D process start with the formation of a team, a clear definition of the problem, and move on to interim containment actions. This is then followed by detailed root-cause analysis using the 8D RCA process, development and verification of permanent corrective actions, implementation, and recurrence preventing efforts. Encouraging details in the analysis: the 8D methodology steps encompass collaborative efforts and documentation that ensure durable solutions and continuous improvement in organizational processes. Root Cause Analysis (RCA) is embedded within the 8D process and includes the following steps and techniques:

Problem Symptom is measured and transformed to “Object and Defect”

Problem Symptom is reformed to Problem Statement using the 5W1H process

Potential Causes are gathered using the tools like Fishbone or Affinity Diagram

Problem Statement should fit using both the “is” and the “isn’t” sections of the question

Root Cause concepts are developed from remaining possible causes on the tool and related changes from is/is not

Compare theories with recent data and develop experiments for Root Cause Verification

Test and confirm the Root Causes

Customer Success

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How to use the 8d approach.

8D portrays 8 steps of a structured approach to solve difficult, recurring, or critical problems by providing transparency, driving a team approach, and increasing the chances of solving the problem.

Proper plan for solving the problem and identify the prerequisites.

Team creation

Gather a cross-functional team with product/process knowledge.

Problem description and definition

Use the data and information to specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many (the 5W1H) for the problem.

Problem Containment Plan development

Develop and implement interim actions to eliminate the problem from any customer in the future.

Specify and assess Root Causes

Identify and review all relevant causes and sources of variation that analyze why the problem has occurred and figure out why the problem was not noticed at first using 5W1H or diagrams.

Verify Permanent Solutions

After collecting data confirm that the possible solutions will actually resolve the problem.

Implement and Validate Corrective Actions

Discuss and review results and develop plans to implement the best solutions or countermeasures.

Preventive measures

Transform the operation systems, management systems, procedures, and practices to avoid the recurrence of similar problems.

Compliment your team

Recognize the collective efforts of your team and formally thank them for their involvement.

8D Problem Solving Tools and Techniques

The 8D problem solving methodology is the set of tools and methods aiming for complex quality issues. 8D for problem solving techniques are basically comprised of a fishbone diagram, 5 Whys analysis, Pareto charts, process flowcharts, and Failure Mode and Effects Analysis (FMEA) to come to terms with the 8D framework. Integration with statistical tools and data analysis in every step of 8D analysis is sure to make the most accurate identification of the root cause.

This approach would ensure that cross-functional teams' participation would not only be present in the brainstorming sessions but also in the 8D problem solving process at the problem solving stage.

Training in 8D Methodology

8D training is an inevitable imperative that makes its deployment in organizations effective. The 8D methodology provides all the necessary details that the teams could apply to the skills and knowledge required at every step in 8D of quality control . Training the workforce on 8D methodology will make them able to apply these aspects when dealing with real-world problems, which will better off the quality and efficiency of the entire organization. It ensures that all these measures and strategies have been inducted to make sure that 8D problem solving approaches are not just tools for problem solution but have been inducted to lay down the base for sustainable quality improvement and prevention practices in the organizational processes.

How to Enhance Quality and Efficiency in 8D Manufacturing?

Understand the Basics of the 8D Approach to Problem Solving

• Familiarize yourself with the principles of the 8D methodology.
• Recognize that the 8D process steps include team formation, problem

Form a Cross-Functional Team

• Assemble a team with diverse skills and perspectives.
• Ensure each member understands their role in the 8D structured problem solving process.
• Use precise language to describe the problem.
• Implement tools like the 5 Whys to aid in the root cause analysis 8d problem solving phase.

Implement Interim Containment Actions

• Take immediate 8D analysis steps to prevent the problem from worsening.
• Document these actions as part of the 8D troubleshooting methodology

Identify and Verify Root Causes

• Conduct a thorough root cause analysis to pinpoint the underlying issues.
• Utilize techniques like fishbone diagrams and Pareto charts in the 8D RCA Process.

Develop Permanent Corrective Actions

• Propose solutions that address the root causes identified.
• Ensure these solutions are sustainable and prevent recurrence.

Validate the Corrective Actions

• Test the solutions to ensure they effectively resolve the problem.
• Collect data to confirm the effectiveness of the root cause analysis and the 8Dd corrective action process.

Implement and Monitor Solutions

• Roll out the verified solutions across relevant areas.
• Continuously monitor the impact to ensure long-term success.

Prevent Recurrence

• Update processes and documentation to incorporate the new solutions.
• Train employees on the new procedures to embed them in daily operations.

Recognize and Celebrate Success

• Acknowledge the efforts of the team in solving the problem.
• Use this opportunity to reinforce the importance of the 8D methodology in maintaining quality and efficiency.

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8D Process Improvement in Different Industries

Automotive Industry

• Application of 8D Methodology : Essential for addressing recurring quality issues and customer complaints.
• Root Cause Analysis 8D Problem Solving : Identifies underlying issues affecting vehicle performance and safety.
• 8D Structured Problem Solving : Used to enhance manufacturing processes and reduce defects.
• 8D Process Steps: Followed rigorously to maintain high safety and quality standards in vehicle production

Aerospace Industry

• 8D Troubleshooting Methodology : Critical for resolving complex technical issues and ensuring compliance with stringent safety regulations.
• 8D RCA Process : Applied to investigate and eliminate root causes of system failures.
• 8D Corrective Action Process : Ensures that preventive measures are implemented to avoid the recurrence of problems.
• 8D Manufacturing : Focuses on precision and reliability in the production of aerospace components.

Electronics Industry

• 8D Approach to Problem Solving : Used to tackle issues related to product design and manufacturing.
• Root Cause Analysis and the 8D Corrective Action Process : Vital for maintaining product quality and reducing warranty claims.
• 8D Process Steps : Helps in identifying and addressing defects in electronic components and assemblies.
• 8D Methodology : Ensures continuous improvement and innovation in electronics manufacturing processes.

Healthcare Industry

• 8D Structured Problem Solving : Applied to improve patient care and operational efficiency in healthcare facilities.
• 8D Problem-Solving Steps: Utilized to address issues related to medical equipment and procedural errors.
• Root Cause Analysis 8D Problem Solving: Enhances patient safety by identifying and eliminating causes of medical errors.
• 8D Troubleshooting Methodology: Ensures that corrective actions are taken to prevent the recurrence of adverse events.

Food and Beverage Industry

• 8D Manufacturing : Ensures product quality and safety throughout the production process.
• 8D Approach to Problem-Solving : Addresses contamination issues and improves production line efficiency.
• Root Cause Analysis and the 8D Corrective Action Process : Essential for maintaining food safety standards.
• 8D Process Steps : Used to investigate and resolve quality issues in food production systematically.

Pharmaceutical Industry

• 8D Methodology : Applied to ensure the consistency and safety of pharmaceutical products.
• 8D RCA Process : Identifies and addresses root causes of deviations in manufacturing processes.
• 8D Corrective Action Process : Implements preventive measures to ensure compliance with regulatory standards.
• 8D Troubleshooting Methodology : Enhances production efficiency and reduces the risk of product recalls.

Consumer Goods Industry

• 8D Structured Problem Solving : Used to resolve product design and manufacturing issues.
• 8D Process Steps : Ensures consistent product quality and customer satisfaction.
• Root Cause Analysis 8D Problem Solving : Identifies and eliminates causes of defects in consumer products.
• 8D Manufacturing : Focuses on improving production processes and reducing waste.

Energy Industry

• 8D Approach to Problem Solving : Applied to address equipment failures and improve operational reliability.
• Root Cause Analysis and the 8D Corrective Action Process : Ensures the continuous improvement of energy production processes.
• 8D Troubleshooting Methodology : Helps resolve complex technical issues in energy plants.
• 8D RCA Process : Identifies and eliminates causes of energy generation and distribution inefficiencies.

8D Process Metrics and KPIs

• Problem Resolution Time: This metric tracks the time taken from problem identification to resolution in the 8D root cause analysis process, ensuring timely corrective actions are implemented to prevent recurrence.
• Recurrence Rate: By measuring how often a similar problem reappears after the 8D corrective action process, this KPI helps assess the effectiveness of the implemented solutions and continuous improvement efforts.
• Root Cause Identification Accuracy: This KPI evaluates the precision and accuracy with which the root causes are identified during the 8D root cause analysis , ensuring that the correct issues are being addressed.
• Corrective Action Implementation Rate: This metric tracks the percentage of corrective actions successfully implemented within the stipulated timeline, indicating the efficiency of the 8D corrective action process.
• Customer Satisfaction Improvement: Monitoring changes in customer satisfaction levels following the 8D corrective action process can highlight the impact of the process on overall product quality and customer perception.

8D Problem Solving Report

8D problem solving reports and templates are useful tools to initiate a problem solving process. These reports are used to explain what 8D is and including information about each step so that one will know what needs to be done by attempting this to solve problems. Keeping these reports easily available can avoid repeating work on the same problems over and over again.

8D reports must be detailed and incorporate information at every step within the 8D process. Those who are working on the problem should provide sufficient information when completing a report so that someone who was not on the current 8D team can pull it out and understand what the problem was and what solutions were implemented.

Improve quality, eliminate problems and identify the root cause of a problem with 8d Methodology

Who can 8d help.

The 8D methodology is universally applicable for every organization that needs solving. Although, there are a few industries and sectors where this 8D approach is successfully used such as manufacturing, the automotive industry , engineering companies that manufacture products or parts, and medium and large-scale enterprises.

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Implementing the 8D Root Cause Analysis

Establish the Team

• Assemble a cross-functional team: Ensure diverse perspectives and expertise.
• Define roles and responsibilities: Clarify each member's contributions.
• Team leader selection: Choose someone with strong leadership and problem-solving skills.

Describe the Problem

• Problem statement creation: Define the issue clearly and concisely.
• Use of data and evidence: Gather and present data to illustrate the problem.
• Scope and impact: Detail how the problem affects processes, products, or customers.
• Immediate actions: Implement temporary measures to contain the problem.
• Verification of ICAs: Ensure the containment actions are effective.
• Monitoring: Continuously monitor the situation until a permanent solution is found.

Determine Root Causes

• Root cause analysis techniques: Utilize tools like the 5 Whys and Fishbone diagrams.
• Data analysis: Examine data to identify patterns and anomalies.
• Identify multiple root causes: Look beyond the obvious to find all contributing factors.

Develop Permanent Corrective Actions (PCAs)

• Brainstorm solutions: Generate potential corrective actions.
• Evaluate effectiveness: Assess the feasibility and impact of each solution.
• Select the best solution: Choose the most effective and sustainable corrective action.

Implement and Validate PCAs

• Action plan creation: Develop a detailed plan to implement corrective actions.
• Execution: Carry out the corrective actions according to the plan.
• Validation: Verify that the corrective actions resolve the problem effectively.
• Standardization: Update processes, procedures, and documentation to include the new solutions.
• Training: Educate employees on the new procedures to ensure consistent application.
• Monitoring and review: Regularly review the effectiveness of the implemented solutions.

Recognize the Team and Celebrate Success

• Team recognition: Acknowledge the contributions of each team member.
• Celebrate achievements: Celebrate the success of solving the problem.
• Document lessons learned: Record insights and lessons learned for future reference.

Quality-centric Companies Rely on CQ QMS

Frequently Asked Questions

The 8D methodology is often used since it provides a consistent, simple, and thorough approach to solving raised problems at various stages. If properly applied, it gives several advantages such as:

A systematic approach for improving team-oriented problem solving skills

A clear understanding of basic statistical tools needed for problem solving

A practical understanding of the ‘ root cause analysis’ tool

Creating and expanding relative information about past failures and lessons learned to avoid future problems in the organization

Improving skills for corrective action deployment

When the team is trying to find the root cause of the problem and deploy corrective actions, some defective products will continue to be manufactured. To prevent these defective parts from reaching the customer, interim containment ensures that the defects are contained in the facility till the problem is completely solved. If defective parts reach the customer, it may result in warranty claims, field failures, and customer complaints.

To implement the 8D process successfully, the following factors are crucial:

The right team

An accurate description of the problem

Avoiding skipping through 8D analysis steps

Ensuring cooperation within the team and management support

Understanding the difference between real causes and possible causes

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8D Training

8d training (onsite).

– Training at Your Facility –

⇓   8D Training Course Details

⇓   8D Training Course Description

⇓   8D Training Course Objectives

⇓   8D Training Course Outline

⇓   Learn More About 8D Training

8D Course Details (Onsite)

When you choose onsite Eight Disciplines of Problem Solving (8D) Training, Quality-One brings the knowledge to you, resulting in immediate benefits for your team. The convenience of Onsite Technical Training has made it a popular option for many of our clients who require five or more participants to be trained.  Expenses are minimal compared to having the whole team travel.

8D Course Description (Onsite)

The Quality-One 8D problem solving training course follows the steps of 8D in a dynamic, instructor-led environment. The course describes to participants the methodologies that have proven to be best practices for effective 8D development. Each participant will be able to interact with all of the elements of the 8D process, including the use of tools such as: Ishikawa/ Fishbone, Affinity Diagrams, Is / Is Not, Process Flow and Comparative Analysis. All activities will include industry-specific examples and terminology.

Participants will learn how to follow the 8D process steps while working in a Cross Functional Team (CFT). They will also practice problem solving tools to support a root cause and eliminate it through permanent corrective action. Participants can expect team activities and relevant exercises in a workshop format. The Quality-One 8D training materials and examples also provide an invaluable resource for review time after time.

8D Course Objectives (Onsite)

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 a Cross Functional Team (CFT)
• Determine effective Interim Containment Action
• Manage and store 8D content (Lessons Learned) for future use
• Ishikawa/Fishbone
• Is / Is Not
• Statistical Process Control (SPC)
• Poka Yoke (Error Proofing)
• Understand links to Control Plan Methodology
• Complete the 8D format correctly

8D Course Outline (Onsite)

Section 1 – 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

Section 2 – Review of Analytical Tools in 8D

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

Section 3 – 8D Process Step by Step

• Problem Symptom
• Quantified Symptom
• Criteria for 8D Continuance
• Roles and Responsibilities
• Team Preparation
• Agenda and Rules
• Core Team and SMEs
• Repeated Why
• Workshop on Problem Statements and Brainstorming
• Workshop on Problem Description Development
• D3 – Interim Containment Action (ICA)
• Human Factors (Operator Error)
• Comparative Analysis
• Root Cause Theories
• Root Cause Verification
• Escape Point
• Workshop on Root Cause Theories
• Methods for Selecting PCA
• Verification of PCA
• Plan, Do, Study, Act (PDSA) Implementation Plan
• Change Management
• Stakeholders
• Validation Criteria and Sample Size
• Processes and Procedures
• Lessons Learned
• Archive of Documents

8D Training (Offsite)

– Training at Our Facility –

8D Course Details (Offsite)

8D Training in a Quality-One Technical Training Center provides participants with a learning environment that is free from interruption from daily activities. This type of course is recommended for individuals or organizations with less than 5 people who require training. Our offsite Eight Disciplines of Problem Solving (8D) Training activities are developed around principles that all participants can relate to. Offsite training also allows participants from different backgrounds and industries to share their viewpoints and experiences. This discussion often helps participants from one industry take advantage of best practices that are used in another.

8D Course Description (Offsite)

This engaging, instructor-led 8D problem solving training course takes participants through each step of the 8D problem solving process. The course offers each participant the knowledge of methodologies which have proven to be the best practices for 8D development. Each participant will be able to interact with all of the elements of the 8D process, including the use of tools such as: Ishikawa / Fishbone, Affinity Diagrams, Is / Is Not, Process Flow and Comparative Analysis.

Participants will learn how to follow the 8D process steps while working in a Cross Functional Team (CFT). They will also practice problem solving tools to support a root cause and eliminate it through permanent corrective action. Participants can expect team activities and relevant exercises in a workshop format. The Quality-One reference materials and examples also provide an invaluable resource for review time after time.

8D Course Objectives (Offsite)

8d course outline (offsite).

• Ishakawa / Fishbone
• 5 Why (3-Legged 5 Why Approach)
• D0 – Prepare (Plan) for the 8D

8D Training (Online)

– Technical Training Overview –

8D Course Details (Online)

The Quality-One Online Eight Disciplines of Problem Solving (8D) Training Overview is an excellent introduction to the 8D methodology. The course is completely interactive, featuring audio, video, animation and downloadable reference materials. Online training gives you immediate access to 8D process content and is available 24 hours a day.

8D Course Description (Online)

Quality-One Online 8D Training Overview introduces participants to the basic principles of 8D, including each step required in the 8D format. Participants will also be able to understand the sequence of the 8D process and receive guidance on what tools are involved with each step. This course follows a structured approach for defining problems and identifying root causes. The participant will have 30 days to complete this course and can access it at any time.

8D Course Objectives (Online)

Upon completion of this overview, the participant will acquire the knowledge to:

• Understand the 8D process and describe each step
• Describe the tools and methods used in support of 8D
• Explain how 8D teams are structured
• Identify Symptoms, Problem Statements, Problem Descriptions, Possible Causes, Most Likely Causes and Root Causes
• Describe Interim Containment and Permanent Corrective Actions
• Explain how Preventative Analysis benefits organizations
• Explain verification vs. validation during problem solving
• Explain how the escape points link to control plans

8D Course Outline (Online)

• Change Induced Problems
• Never Achieved Problems
• Ishakawa Fishbone
• 5 Why (3-legged Approach)
• D3 – Interim Containment Action
• Root Cause theories
• PDSA Implementation Plan
• D8 – Closure and Congratulate the Team

Learn More About 8D Training

Quality-One offers Quality and Reliability Support for Product and Process Development through Consulting, Training and Project Support. Quality-One provides Knowledge, Guidance and Direction in Quality and Reliability activities, tailored to your unique wants, needs and desires. Let us help you Discover the Value of 8D Consulting , 8D Training or 8D Project Support .

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(248) 280-4800 | [email protected]

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8D Methodology

In this topic, 8d internal report, 8d customer report, 8d action items, d0: prepare, d1: gather the team, d2: describe the problem, d3: implement interim containment, d4: identify and verify root cause, d5: define and verify corrective action, d6: implement and validate corrective action, d7: prevent recurrence, d8: celebrate team success.

• Who and what does the problem affect?
• What is the root cause of the problem?
• What temporary containment actions can we take to protect the customer?
• What permanent corrective actions can we take to prevent similar problems in the future?
• D0: Prepare : Gather data and collect feedback to determine if 8D is the right methodology to solve the problem.
• D1: Gather the Team : Establish a cross-functional team that has the right level of skills, competencies, and technical expertise to address the problem.
• D2: Describe the Problem : Define the problem in quantifiable terms and focus on the symptoms, its impact on the customer, when and where it occurred, and any other relevant details. Use evidence to support your claims.
• D3: Implement Interim Containment : Identify, evaluate, and implement immediate actions to contain the problem to keep customers informed and protected.
• D4: Identify and Verify Root Cause : Use various problem-solving tools and techniques to identify and analyze the underlying cause of the problem.
• D5: Define and Verify Corrective Action : Develop and implement corrective actions to eliminate the source of the problem and prevent it from recurring.
• D6: Implement and Validate Corrective Action : Test and monitor the corrective actions to verify that the problem does not exist anymore.
• D7: Prevent Recurrence : Develop long-term actions, such as process changes, monitoring, and training to ensure that the problem does not recur.
• D8: Celebrate Team Success : Recognize the team as well as individual contributions and document lessons learned for future projects.
• What are the key details from each phase?
• What actions did the team take at each phase?

The data in this form is shared with the 8D phase forms. Any data you enter in this form automatically populates the forms that share this data and vice versa. At the end of the project, the 8D Internal Report will be complete and serve as a summary of the project for the team.

• Initially, enter as many details about the project as possible.
• If necessary, edit the form.
• What is the customer's claim?
• What evidence supports the claim?
• What corrective actions did you take to resolve the problem?

The data in this form is shared with the 8D phase forms. Any data you enter in this form automatically populates other forms that share this data and vice versa. At the end of the project, this form will be complete and ready to share with the customer.

• After gathering initial information about the problem, enter details about the customer's claim.
• Summarize the root cause of the problem and any evidence to support the customer's claim.
• Summarize the corrective action plan.
• After your organization implements the corrective action plan, update this form to include evidence of the improvement.
• Provide the customer with a copy of this report.
• What actions did the team take at every phase of the project?
• Who was responsible for each action?
• What is the status of each action?
• Throughout the project, add any new action items that occur as you move through each phase of the 8D methodology.
• Monitor and update the status of each item.
• Refer to this form as a historical record of the steps you took to address the problem and prevent it from happening in the future.
• Is the 8D methodology the appropriate approach to this problem?
• What resources are required to solve the problem?
• Is an emergency response necessary?
• Determine if the 8D methodology is appropriate, then justify your decision to proceed.
• Document the tracking data for the project, including start and end dates, the customer claim, and any affected parts.
• Determine the time and effort required to complete the project.
• Identify the necessary technical skills and competencies of the people required to solve the problem.
• Use a Risk Matrix to determine if an Emergency Response action plan is necessary, and if so, describe the plan. For more information, go to Risk Matrix .
• Who are the team members?
• Are all team members qualified and available?
• Who will be responsible for leading the project?
• After you determine if 8D is appropriate, determine who has the skills, experience, availability, and authority to be an effective team member.
• (Optional) Use the RACI (Responsibility Assignment Matrix) form to identify the team members and clarify their roles on the team. For more information, go to RACI (Responsibility Assignment Matrix) .
• Identify the project leader and champion.
• Add all team members and their contact information to the table.
• What is the problem?
• How does the problem impact the customer?
• What quantifiable evidence of the problem do we have?

Use the CATWOE and the Is/Is Not forms during this phase to help you define the problem and narrow its scope. For more information, go to CATWOE and Is/Is Not .

• After you establish your team in phase D1, gather as a team to define the problem. Identify what is happening, where it is happening, when it occurs, and who it impacts.
• Collect any evidence of the problem, including data and images, and add these items as related documents and/or hyperlinks to the roadmap of the 8D Project template.
• Create a specific, measurable, and well-documented problem statement based on your findings and the data you collected.
• From the problem statement, define the scope so the team can collectively set goals and establish a timeline for the project.
• Update the 8D Action Items form.
• What is the immediate problem?
• How can we prevent it from getting worse?
• After you clearly define the problem in phase D2, issue a Quality Alert (see below) to inform customers of the problem, what they can do until you implement a permanent solution, and what they can expect until then.
• Use a brainstorming tool to brainstorm potential containment solutions.
• Use a Solution Desirability Matrix to determine the best solution, then describe the solutions you considered and which one you plan to pursue. For more information, go to Solution Desirability Matrix .
• Summarize your Interim Containment Plan.

Quality Alert

A Quality Alert form ensures that you manage the problem promptly and systematically.

• Who should you notify about the problem?
• What will the notification be and who is responsible for it?
• When and how will you deliver the notification?
• Document the details of the problem including the date, time, and location of its discovery and information about the product, processes, or equipment involved.
• After analyzing the problem, determine its impact on the customer.
• Document what actions the customer can take to address immediate issues and what they should expect as a follow-up from your organization.
• Itemize the deliverables you plan to produce to address the problem and communicate this information to your customers.
• Include the purpose of each deliverable, who will deliver it (owner), who will receive it (audience), and when and how they will receive it.
• What is the problem's root cause?
• What is the problem's escape point, or the earliest point at which the problem should have been detected, but was not?
• What tools were used to investigate the problem?
• After you implement the interim containment plan from phase D3, use a Fishbone diagram to brainstorm likely causes of the problem. Next, use the Five Whys form to help narrow the likely causes. For more information, go to Fishbone and Five Whys .
• Perform a root cause analysis. Summarize the results of your analysis and how you verified the actual root cause. Be sure to include any tools that were used in your analysis and verification and link them to the project.
• Use a Fishbone diagram to brainstorm likely escape points. Summarize the results of this exercise and how you verified the actual escape point.
• Update the 8D Action Items Items form.
• What corrective action will best solve the problem?
• Does the corrective action have any potential side effects or negative consequences?
• Based on your findings from the D4 phase, summarize the corrective actions you plan to take to eliminate the problem's root cause.
• Use a PFMEA to identify the causes of failure and evaluate the risks associated with each cause. For more information, go to FMEA .
• Use an Impact Analysis to identify who and what are impacted by potential change to evaluate the severity of the impact. For more information, go to Impact Analysis .
• Based on the results of the PFMEA and Impact Analysis , determine if there are any side effects from the corrective actions you plan to take. If so, summarize how you plan to mitigate them.
• Did corrective actions result in a significant improvement?
• What evidence do we have to verify that the corrective actions were effective?
• After you implement the corrective actions, collect data to assess and verify the results.
• Use a 2-Sample t Test to compare past performance with current performance.
• Use Control Charts and Time Series Plots to monitor the results of the corrective actions.
• Gather feedback from customers to ensure the corrective actions resolved the problem from their perspective.
• Summarize your data collection methods and any evidence of the improvement. Include any data sets or graphs.
• Document any unexpected side effects the corrective actions caused and how you addressed them.
• Do we need to change any systems, processes, or procedures to prevent the problem from happening again?
• What internal documentation do we need to update to support these changes?
• Who needs to be aware of these changes?
• Use a brainstorming tool to identify potential systemic failures that could lead to a recurrence of a similar problem in other areas, such as product lines, departments, or locations.
• After you identify potential systemic failures, use a process map to reflect any proposed process changes to prevent these potential failures.
• Use a Solution Implementation Checklist to document items to consider before you implement any proposed process changes. For more information, go to Solution Implementation Checklist .
• After you determine which proposed changes to implement, complete a Communication Plan to ensure that you can effectively communicate the proposed process change. For more information, go to Communication Plan .
• Identify, review, and update any internal documentation affected by the proposed process change.
• Implement the process change, then communicate the change to the affected personnel.
• What did we accomplish as a team?
• How did each team member contribute to the team's success?
• What lessons did we learn?
• At the end of the project, gather as a team to celebrate your success and complete the Project Retrospective and Lessons Learned form (see below).
• Acknowledge the effort and commitment of the team.
• Recognize and appreciate each team member and their individual contributions.
• Share success stories and lessons learned from the experience.
• Encourage team members to provide feedback on what went well and what did not go well to foster a positive work environment and open communication.

Project Retrospective and Lessons Learned

• What went well?
• What did not go well?
• What did we learn from the project?
• As a group, share what went well and what did not go well throughout the course of the project.
• From this discussion, identify issues that affected productivity or quality of work. Try to recognize and understand patterns or themes that contributed to the teams' successes and challenges.
• Based on this insight, generate specific action items for future improvements.
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8D Problem-Solving: Common Mistakes to Avoid

Author: Daniel Croft

Daniel Croft is an experienced continuous improvement manager with a Lean Six Sigma Black Belt and a Bachelor's degree in Business Management. With more than ten years of experience applying his skills across various industries, Daniel specializes in optimizing processes and improving efficiency. His approach combines practical experience with a deep understanding of business fundamentals to drive meaningful change.

In today’s competitive business landscape, effective problem-solving is the cornerstone of organizational success. The 8D Problem-Solving methodology offers a structured, team-based approach to tackle challenges head-on. Yet, while many rush to employ its eight disciplines, few navigate its intricacies without stumbling. Whether you’re a seasoned professional or new to the 8D realm, recognizing and sidestepping common mistakes is pivotal. In this article, we unveil the most frequent blunders that teams unwittingly commit, providing insights to enhance your problem-solving prowess. Dive in to discover these pitfalls and ensure your 8D approach is both efficient and impactful.

The 8D method is a popular way teams solve problems step-by-step. It’s like a roadmap that helps teams figure out what went wrong and how to fix it for good. Many businesses love using it because it’s organized and gets results. But, like anything, there are some common mistakes people make when using this method. In this article, we’ll talk about those mistakes and give tips on how to avoid them. By the end, you’ll know how to use the 8D method even better and make sure your team gets the best results.

1. Skipping Steps

Background:.

The 8D problem-solving process is designed as a step-by-step approach to ensure that teams address problems comprehensively and systematically. Each step plays a crucial role in understanding, diagnosing, and resolving the issue at hand.

One common pitfall is the temptation to skip or rush through certain steps. This often occurs because teams believe they have a grasp of the problem based on preliminary observations or past experiences. Especially in the initial stages—where defining and describing the problem is crucial—this oversight can result in a superficial understanding, leading to ineffective or misaligned solutions.

By not giving each step its due diligence, teams risk:

• Misdiagnosing the real issue
• Implementing solutions that don’t address the root cause
• Wasting resources on ineffective strategies

How to Avoid:

To counteract this, it’s vital to treat each step with equal importance, resisting the urge to jump ahead. A thorough understanding of the problem, achieved by diligently following each step, lays the foundation for effective solutions. Regular checkpoints can also be established to ensure that each step has been comprehensively addressed before progressing.

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2. Not Forming a Diverse Team

The essence of the 8D problem-solving approach is collaborative teamwork. The collective insights, experiences, and skills of a team often lead to more innovative and effective solutions than individual efforts.

A frequent oversight is forming teams where members have similar backgrounds, experiences, or perspectives. Such homogeneity can lead to a narrow viewpoint, where potential solutions or root causes might be overlooked.

A homogeneous team can result in:

• Limited creativity and innovation
• Overlooking potential solutions or root causes
• Confirmation bias, where members validate each other’s perspectives without critical evaluation

To ensure a holistic understanding of the problem and a diverse range of solution options, teams should be multidisciplinary. This means including members from various departments, roles, and, if necessary, external stakeholders. Such diversity brings a plethora of perspectives, fostering rich discussions, challenging established norms, and ensuring that the problem is viewed from all possible angles.

3. Failing to Document Everything

Documentation is the backbone of a structured problem-solving process like 8D. It provides a tangible trail of the team’s journey, from problem identification to solution implementation.

Teams often become so engrossed in discussions, brainstorming sessions, and solution implementation that they forget or deemphasize the importance of documentation. This oversight can stem from a belief that the issue at hand is straightforward or that team members will remember crucial details.

Neglecting documentation can lead to:

• Loss of vital information, especially if team members change or are unavailable.
• Inconsistencies in understanding or approach, as verbal discussions may be interpreted differently by different members.
• Difficulty in tracking progress or revisiting decisions when needed.
• Challenges in replicating the solution process for similar problems in the future.

To ensure thoroughness and continuity, teams should maintain detailed records at every stage. This includes documenting:

• Problem descriptions
• Data gathered
• Analysis results
• Discussions and brainstorming sessions
• Decisions made and their rationale
• Implemented solutions and their outcomes

Using collaborative tools or platforms can help streamline this process and provide a centralized repository accessible to all team members.

4. Not Validating Root Causes

Identifying the root cause of a problem is pivotal in the 8D approach. It ensures that solutions address the underlying issue, not just the symptoms.

In their eagerness to resolve the problem, teams sometimes latch onto the first plausible cause they identify. This premature conclusion can stem from confirmation bias, where individuals seek out information that confirms their existing beliefs.

Settling on an unvalidated cause can result in:

• Implementing solutions that don’t address the real issue.
• Recurrence of the problem, leading to increased costs and wasted resources.
• Frustration and reduced morale, as teams feel they are repeatedly addressing the same issues.

Teams should employ a rigorous validation process for identified root causes. This can involve:

• Asking “Why?” repeatedly (typically five times) to drill down into the underlying cause—a technique known as the “ 5 Whys .”
• Using structured analytical tools like Fishbone diagram s (also known as Ishikawa or Cause and Effect diagrams) to explore all potential causes in a systematic manner.
• Testing the hypothesized root cause in real-world scenarios to see if addressing it resolves the problem.

5. Implementing Quick Fixes

In the face of pressing problems, there’s often a natural inclination to find the quickest way to alleviate the immediate pain or visible symptoms. This can lead to teams opting for “band-aid” solutions or quick fixes.

Choosing the path of least resistance or the fastest remedy often means addressing only the surface-level symptoms of a problem, rather than its root cause. This approach can be driven by time constraints, pressure from stakeholders, or a desire for immediate relief.

Relying on quick fixes can lead to:

• Recurrence of the problem, as the underlying cause remains unaddressed.
• Wasting resources on repetitive, short-term solutions.
• Eroding trust and confidence, as stakeholders see the same issues resurface.

To sidestep the pitfalls of quick fixes:

• Prioritize solutions that address the root cause of the problem, even if they take longer to implement.
• Educate stakeholders on the importance of sustainable solutions, emphasizing the long-term benefits over short-term relief.
• Allocate adequate time and resources for comprehensive problem-solving, recognizing that a deeper fix now can prevent repeated issues in the future.

6. Failing to Monitor the Effectiveness of Corrective Actions

The journey of problem-solving doesn’t end with the implementation of a solution. Continuous monitoring is essential to ensure that corrective actions deliver the desired results.

Once a solution is in place, teams might move on to other tasks, assuming that the problem is resolved for good. This complacency can stem from a belief that the implemented solution is foolproof or from a lack of resources dedicated to monitoring.

Not monitoring the effectiveness of corrective actions can result in:

• Unnoticed failures or inefficiencies in the implemented solution.
• Missed opportunities for improvement or optimization.
• Stakeholder dissatisfaction if the problem resurfaces or new issues emerge.

To ensure that corrective actions remain effective:

• Set up regular review intervals to assess the performance of the implemented solution.
• Define clear metrics or KPIs to objectively measure the success of the corrective actions.
• Foster a culture of continuous improvement, where teams are encouraged to iterate and refine solutions based on real-world feedback.
• Ensure open channels of communication with stakeholders to gather feedback and address any emerging concerns promptly.

7. Not Preventing Recurrence

Solving a problem doesn’t only involve addressing its current manifestation but also entails preventing its reoccurrence. This proactive approach ensures long-term success and stability.

Teams might focus so intently on resolving the immediate issue that they neglect to consider its potential to resurface. This oversight can be due to time constraints, a lack of comprehensive analysis, or simply underestimating the problem’s complexity.

Failing to prevent recurrence can lead to:

• Repeatedly addressing the same issues, leading to wasted time and resources.
• Erosion of stakeholder confidence as the problem keeps reappearing.
• Additional costs and disruptions associated with recurrent problems.

To ensure problems don’t keep reoccurring:

• Conduct a thorough post-mortem analysis to understand the factors that contributed to the problem’s occurrence.
• Identify and address any systemic vulnerabilities or gaps that might allow the problem to resurface.
• Implement preventive measures, which could include training, system upgrades, or process changes.
• Regularly review and update these measures based on new insights or changing circumstances.

8. Forgetting to Recognize the Team’s Efforts

Behind every problem-solving endeavor is a team of dedicated individuals working collaboratively. Recognizing their efforts is not only a sign of gratitude but also an essential component of team dynamics and motivation.

In the rush to move on to the next task or project, teams might forget to pause and acknowledge the hard work that went into solving the problem. This oversight can be unintentional, but its impact on team morale can be significant.

Not recognizing the team’s efforts can result in:

• Diminished motivation and engagement among team members.
• A feeling of being undervalued or overlooked, which can hamper future collaboration.
• Reduced willingness to go the extra mile in future projects or tasks.

To ensure teams feel valued and motivated:

• Set aside time at the end of a project or task for reflection and acknowledgment.
• Celebrate successes, no matter how small, through team gatherings, awards, or simple words of appreciation.
• Foster a culture where team members regularly acknowledge and praise each other’s contributions.
• Encourage feedback and provide opportunities for team members to share their experiences and learnings.

In problem-solving, the 8D methodology stands out for its structured and comprehensive approach. However, even within such a robust framework, pitfalls await the unwary. From the temptation of quick fixes to the oversight of not preventing recurrence, these challenges can undermine the effectiveness of solutions. Moreover, the human element—recognizing and valuing the team’s contributions—is just as pivotal as the technical steps. To truly harness the power of 8D, it’s essential to be cognizant of these common mistakes and proactively work to sidestep them. By doing so, teams not only address current issues effectively but also lay the foundation for sustainable success and continuous improvement in their organizations.

• Zarghami, A. and Benbow, D.W., 2017.  Introduction to 8D problem solving . Quality Press.
• Camarillo, A., Ríos, J. and Althoff, K.D., 2017.  CBR and PLM applied to diagnosis and technical support during problem solving in the Continuous Improvement Process of manufacturing plants .  Procedia Manufacturing ,  13 , pp.987-994.

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Daniel Croft

Hi im Daniel continuous improvement manager with a Black Belt in Lean Six Sigma and over 10 years of real-world experience across a range sectors, I have a passion for optimizing processes and creating a culture of efficiency. I wanted to create Learn Lean Siigma to be a platform dedicated to Lean Six Sigma and process improvement insights and provide all the guides, tools, techniques and templates I looked for in one place as someone new to the world of Lean Six Sigma and Continuous improvement.

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