8D problem solving
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Problem solving techniques Sandeep Bangera 17 th May 2013 8D- Methodology
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Transcript of 8D problem solving
Problem solving techniques
Sandeep Bangera 17th May 2013
8D- Methodology
15/2/2012
Gap between existing state and the desired state
Quality problems
Design
Product Processes
Performance
Conformance Problem
Efficiency problem
Unstructured performance
problem
Source: Quality management journal, Fall 1994Figure 1: Problem in Quality management
Problem
Problem Problem solving 8D Conclusion 8D-template
8D Methodology 2 17/05/2013
Low risk High risk
Simple
When do we apply structured problem solving methods??Highly Complex
Buying Bread
Baking Bread
Playing Blackjack
Deciding where to build a factory
Minimal/no structure
Follow loosely
Use shortcuts
Use formal process
Figure 2: Risk and complexity analysis
Problem Solving
Problem Problem solving 8D Conclusion
8D Methodology 3
8D-template
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Figure 3: Shewhart Cycle or Deming’s CycleSource: Quality management handbook, pg. 41, Dec . 2005
Problem Solving steps
Problem Problem solving 8D Conclusion
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8D-template
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Source: Quality management, 2nd edition, Pearson education, upper saddle river, NJ
Figure 4: Deming’s cycle with tools
Problem Solving steps with tools
Problem Problem solving 8D Conclusion
8D Methodology 5
8D-template
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1974: Used by US Defence Department in a military standard.
1987: Ford company popularised the 8D concepts • Preliminary data of the problem D0• Establishing the Team D1• Problem description D2• Containment action D3• Identify the root cause D4• Identify Permanent Corrective action D5• Validating the corrective action D6• Prevent recurrence D7• Verify and congratulate teamD8
Figure 5: 8D Methodology
Problem Solving Methodology8D
Problem Problem solving 8D Conclusion
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8D-template
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D1
Interdisciplinary team with:-
• Right skills
• Experience
• Authority
Objective of team Captain:
• Common goal
Establishing the team
Picture: The zenith of enthusiasm: The strength of team work
Figure 6: Team formation
Problem Problem solving 8D Conclusion
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8D-template
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D2 Problem Description
“ A problem well described is half solved”
Problem must be:
• Clearly described
• Scale of problem
• Place of occurrence
•Measurable
•Well communicated
• Tools -WWWWWH, Pareto & control charts
•Mapping out the process with a sketch
Figure 7: Pareto chart
Figure 8: WWWWWH
Problem Problem solving 8D Conclusion
8D Methodology 8
8D-template
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D3 Containment action
Implement containment actions to prevent non-conformance products.
• Company’s end of the line • Customer side of the line• Customer stock • Company’s stock.
D4 Root cause analysis
Why? To ensure effective corrective action aimed at permanent solution. How? Using appropriate systematic approach:-brainstorming, FMEA, 5 why’s, CE , Is or Is not analysis etc. to identify root cause Check sheet, histogram, comparison plots etc. to evaluate stratification factors
Problem Problem solving 8D Conclusion
8D Methodology 9
8D-template
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Figure 10: Fishbone diagramFigure 9: 5 Why tool
Root cause analysis tools: 5 why’s, Fishbone diagram etc.
Problem Problem solving 8D Conclusion
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• Project management schedule
• Validation of PCA using SPC and FMEA under real test condition.
• If not, revisit step D2-D5.
D5 Identify permanent corrective action (PCA)
• Identify PCA on basis of the root cause analysis.
• Preparation of feasibility study for the PCA
How?
• Solution on basis of root cause.
• Statistical process control (SPC)
• FMEA
D6 Implement & Validating corrective action
Problem Problem solving 8D Conclusion
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8D-template
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D7 Prevent recurrence
• Revise the system flow and procedures
•Make system changes to prevent recurrence
• Standardize the new practices
• Notify all departments of the resolution
• Document lesson learnt and archive the document
D8 Congratulate team
• Celebrate your team success
Problem Problem solving 8D Conclusion
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8D-template
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Conclusion •8D methodology is a structured approach of problem solving for quality problems.
•Model can used to solve problems in business operations, Customer complaint, internal complaints, complaints lodged on the supplier.
•Model raises the level of quality thus reducing the costs of defects.
8D
Problem Problem solving 8D Conclusion
8D Methodology 13
8D-template
Figure 11: 8D methodology17/05/2013
8D Methodology 14
8D template of company ABB
Problem Problem solving 8D Conclusion 8D-template
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Problem Problem solving 8D Conclusion
8D Methodology 15
References
• Gerald F Smith, Quality problem solving, American society of quality, 1998.
• 6ixsigma.org, 8D book,
Available at: http://6ixsigma.org/8d-book.aspx [Accessed: 25 Apr 2013]
• Problem solving, Quality Management handbook, December 2005.
• Uzair Rajput, 8D- problem solving method, Quality management handbook
• Fideltronik, 8D-problem solving methodology
• Marjanca Krajnc, 8D-methodology, Journal of universal excellence, October 2012.
• Bill Arnott, 8D-problem solving methodology, Canada.
• ABB, 8D problem solving template, http://www05.abb.com/global[Accessed: 25 Apr 2013]
17/05/2013
Contact Details: Email: [email protected]
