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8D Problem Solving - Automotive Industry

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Introduction to 8D problem solving methodology.

Introduction to 8D problem solving methodology.

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  • 1. 8D Problem Solving
    Automotive Industry
  • 2. Introduction
    2 words would summarize
    this presentation :
    Gemba (現場)
    8D
  • 3. Introduction
    Gemba (現場)
    « Actual location of the issue »
  • 4.
  • 5. Gemba Attitude
  • 6. 8D
    = 8 Do
    = 8 Disciplines
    = 8 Steps
  • 7. 8D:
    Systemic problem solving
    methodology, introduced
    by Ford Motor Company
    late 80’s
  • 8. Do 1:
    Establish a team
  • 9. As soon as a customer claim is received, establish
    a multi-skilled team
  • 10. Multi-skilled:
    Quality, Process Engineering,
    Production Engineering,
    R&D, Lab
  • 11. And most important:
    a line member
  • 12. Do 2:
    Define the problem
  • 13. « A problem well stated is a problem half solved »
  • 14. WWWWWH:
    Who, What, Where, When, Why, How
  • 15. Pareto
    Also called 80-20 rule
  • 16. Support your problem description
    by a picture or a sketch
  • 17. Gemba :
    Recover as much as required defective parts
  • 18. Duplication Tests:
    Try to reproduce the issue
  • 19. Red Rabbit :
    Pass the defective part through the process
  • 20. Do 3:
    Implement Containment
  • 21. Containment consist in stopping the bleeding…
  • 22. … through stock sorting
  • 23. … rework,
  • 24. … enhanced end of line check, etc.
  • 25. Once containment is agreed among the team, …
  • 26. It is necessary to validate it:
    FMEA, Function, Durability, etc
  • 27. Once validated, implementation follows steps …
  • 28. Step 1 : Implement at
    Customer side of the line
  • 29. Step 2 : Implement at
    customer stocks
  • 30. Step 3 : Implement at
    supplier (your) stock
  • 31. Step 4 : Implement at
    your End Of Line
  • 32. Step 5 :
    Include containment into
    manufacturing process
  • 33. Do 4:
    Identify root cause
  • 34. Make sure you
    are looking for
    root-cause !
  • 35. Most known example
    is engine oil level issue …
  • 36. … instead of looking for oil leakage underneath the vehicle, member just add oil !
  • 37. Few methods would support your root-cause analysis …
  • 38. Ishikawa:
    Cause-Effect Diagram, 6M, Fishbone Diagram
    Machines
    Methods
    Materials
    Measurement
    Personnel
    Environment
  • 39. 5 why’s :
    Ask as much as required the question « Why ?»
  • 40. Failure Tree Analysis (FTA)
  • 41. Reverse Engineering:
    Part by part disassembly until identifying root-cause
  • 42. Do 5:
    Choose and verify Permanent Corrective Actions (PCAs)
  • 43. Once root-cause identified,
  • 44. PCAs are agreed within the team…
  • 45. Once again, validation is a must:
    FMEA, Function, Durability, etc
  • 46. Do 6:
    Implement PCAs
  • 47. Implementation
    = Project Management
  • 48. Do 7:
    Prevent recurrence
  • 49. Identify lessons learned
  • 50. Update procedures & documents
  • 51. Including DFMEA and Control Plan
    Update procedures & documents
  • 52. #8
    Congratulate the team!
  • 53. Tips & Tricks before
    Conclusion
  • 54. Tips & Tricks before
    Conclusion
    Speak with facts !
  • 55. Tips & Tricks before
    Conclusion
    Don’t judge. Don’t blame.
  • 56. Tips & Tricks before
    Conclusion
    ( Visualize )
    ( Visualize)
  • 57. Tips & Tricks before
    Conclusion
    Example of
    visualization
  • 58. Tips & Tricks before
    Conclusion
    Example of visualization
  • 59. Tips & Tricks before
    Conclusion
    Example of
    visualization
  • 60. Conclusion
    Conclusion
  • 61. Conclusion
    Gemba = A mindset
    8D = A discipline
  • 62. Thank you for your attention
    Thank you for your attention
  • 63. More ressources on :
    http://gestionprojetauto.wordpress.com
  • Share this presentation
  • 67. Available Trainings
    Project Management
    Problem Solving Methodology (8D)
    Functional Analysis
    Design FMEA (DFMEA)
  • 68. Imad Tamir - イマヅ タミル
    Automotive Project Management : Training, Coaching
    • imad.tamir@gmail.com
    (c) Copyright 2009-2010

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