8D_training_material

1,8D-Methodology,8D-Methodology,2,Overview: the 8D Problem Solving Methodology is a systematic approach used for solving the real problems, the method helps to quickly find a full answer to the problem , Importance of the 8D report: the 8D Report is part of the 8D methodology , after completion of each step. The report is issued/updated by the team and additional documentation is attached as required, the 8D Report is used for monitoring progress and as a checklist, it ensures that all steps of the 8D process have been completed.the report reflects the current state of the problem solving work and is a living document. It can help teams and individuals to fix problems more speedily in future.,8D-Methodology,3,Input: A complex problem has to be resolved Task: Set up a team with relevant expertise Output: A powerful problem solving team,Tackle the problem as a team: Set up a small team, consisting of people who have relevant process and product knowledge, are willing to collaborate and who have the time, competence and technical expertise to solve the problem and initiate corrective action. The team must have a leader.,1.Use Team Approach,8D-Methodology,4,8D Checklist,1D - Team: 1.team member:3-10 members 2.relevant and necessary experts involve the team 3.clarify each members responsibility:team leader and team member 4.clarify the reporting method,5,Input: Powerful problem solving team Task: Specify existing problem with sufficient accuracy Output: Full problem specification Specify the problem: Use Problem Analysis to define the internal/external customers problem as accurately as possible.Bring out the core of the problem and quantify it. Collect and analyze data using statistical methods.,2.Describe the Problem(and verify),8D-Methodology,6,8D Checklist,2D - Problem Description and verify: 1. which customer refer this problem? 2. problem already known from prior cases? 3.visual inspection necessary? 4.mechanical inspection necessary? 5.electrical test necessary? 6.elements of problem identify clearly 7.descripte the problem with pictures/datas/others 8.whether need to break the problem into subproblem? 9.does the customer accept our description?,7,Input: Full problem specification Task: Protection of the customer against the influence of the problem by containment actions Output:Containment actions agreed with the customer Initiate containment action and check its effectiveness: Initiate measures which minimize the influence of the problem on the customer until a permanent solution has been found. Check the effectiveness of these containment actions continuously and if necessary, arrange for further action to be taken.,3. Implement and Verify containment Action,8D-Methodology,8,8D Checklist,3D - Containment Action: 1.risk assessement and,if : -reliability problems -line stop at the customer -reduce outgoing quality 2.possible containment actions: -additional test before shipment(sample based or 100%) -freezing of deliveries;(SHN) -call back from customer or field -rework at customer 3. define the containment actions 4. after the containment action should have a monitoring plan/ procedure. 5. document the containment action and inform all the people involved and affected.,9,Input: Full problem specification Task: Finding the true cause of the problem Output: True cause Identify the true cause(s) and check, whether it/they are really the true cause(s): Check whether the task can be carried out with the current team composition and make changes to the team if necessary. Use Problem Analysis to look for all the causes which could possibly explain the problem. Identify the possible cause(s)and test, by comparison with the problem specification and the existing data, whether a given possible cause is the most probable cause. Verify the most probable cause as being the true cause.,4. Find Root Cause,8D-Methodology,10,8D Checklist,4D - Root Cause: 1.identify prossible root cause owners 2.analyse all the possible deviation from: -suppliers - equipment/tools -staff -processes -environment 3. find the root cause of failure mechanism 4. identify the escape cause.,11,Input: True cause Task: select and verify corrective action for removing true or root cause Output: corrective actions which can remove the root cause Define the corrective action to be taken and check its effectiveness: Check whether the task can be carried out with the current team composition and make changes to the team if necessary. Look for all possible measures which could remove the causes and could solve the problem. Use Decision Analysis to select the optimum permanent corrective measures and verify,5.Select corrective action,8D-Methodology,12,8D Checklist,5D . Corrective Action and Verification: 1.identify possible corrective action by: -former corrective action from complaint /GTR/Hold Tag -define new corrective actions 2.select and verify corrective actions -evaluate these actions -risk analyse for this actions -verify the action in production trials 3.accurately specify the action(who ,when , what , where),13,Input: Cause removed by corrective action Task: Canceling containment action and adopting the corrective action Output: New standardized process sequence Implement the corrective actions and check their effectiveness: Check whether the task can be carried out with the current team composition and make changes to the team if necessary. Use Potential Problem Analysis to set up an action plan for introducing the corrective action(s)and define the running checks to be made to ensure that the cause of the problem has really been removed.,6. Standardize Process,8D-Methodology,14,8D Checklist,6D - Implementation of Permanent Corrective Action: 1.implement the corrective action and document the implementation. 2.Define and implement the monitor plan 3.Evaluate the corrective action effectivness(monitor parameter meet target?) 4.Cancel the containment action. 5.Whether need to develop the corrective action. 6.effective date?,15,Input: New standardized process sequence Task: Preventing renewed occurrence of this or similar problems Output: Prevention with TQM Define measures to prevent recurrence of the problem: Check whether the task can be carried out with the current team composition and make changes to the team if necessary. Modify the management and control systems, instructions, and usual procedures as necessary.Use Think Beyond the Fix in order to prevent recurrence of the same or similar problems in this or other places.,7. Prevent Recurrence,8D-Methodology,16,8D Checklist,7D - Prevention: 1.consider whether the systems, regulations, procedures etc, that maybe affected by the corrective actions need review and update 2.consider other products , processes, prodution lines ,locations etc. Where the similar corrective action is possible and suitable.