8D Problem Solving - Automotive Industry

8D Problem Solving
Automotive Industry

Introduction
2 words would summarize
this presentation :
Gemba (現場)
8D

Introduction
Gemba (現場)
« Actual location of the issue »

Gemba Attitude

8D
= 8 Do
= 8 Disciplines
= 8 Steps

8D:
Systemic problem solving
methodology, introduced
by Ford Motor Company
late 80’s

Do 1:
Establish a team

As soon as a customer claim is received, establish
a multi-skilled team

Multi-skilled:
Quality, Process Engineering,
Production Engineering,
R&D, Lab

And most important:
a line member

Do 2:
Define the problem

« A problem well stated is a problem half solved »

WWWWWH:
Who, What, Where, When, Why, How

Pareto
Also called 80-20 rule

Support your problem description
by a picture or a sketch

Gemba :
Recover as much as required defective parts

Duplication Tests:
Try to reproduce the issue

Red Rabbit :
Pass the defective part through the process

Do 3:
Implement Containment

Containment consist in stopping the bleeding…

… through stock sorting

… rework,

… enhanced end of line check, etc.

Once containment is agreed among the team, …

It is necessary to validate it:
FMEA, Function, Durability, etc

Once validated, implementation follows steps …

Step 1 : Implement at
Customer side of the line

customer stocks

supplier (your) stock

your End Of Line

Step 5 :
Include containment into
manufacturing process

Do 4:
Identify root cause

Make sure you
are looking for
root-cause !

Most known example
is engine oil level issue …

… instead of looking for oil leakage underneath the vehicle, member just add oil !

Few methods would support your root-cause analysis …

Ishikawa:
Cause-Effect Diagram, 6M, Fishbone Diagram
Machines
Methods
Materials
Measurement
Personnel
Environment

5 why’s :
Ask as much as required the question « Why ?»

Failure Tree Analysis (FTA)

Reverse Engineering:
Part by part disassembly until identifying root-cause

Do 5:
Choose and verify Permanent Corrective Actions (PCAs)

Once root-cause identified,

PCAs are agreed within the team…

Once again, validation is a must:
FMEA, Function, Durability, etc

Do 6:
Implement PCAs

Implementation
= Project Management

Do 7:
Prevent recurrence

Identify lessons learned

Update procedures & documents

Including DFMEA and Control Plan
Update procedures & documents

#8
Congratulate the team!

Tips & Tricks before
Conclusion

Conclusion
Speak with facts !

Conclusion
Don’t judge. Don’t blame.

Conclusion
( Visualize )
( Visualize)

Conclusion
Example of
visualization

Conclusion
Example of visualization

Conclusion
Example of
visualization

Conclusion
Conclusion

Conclusion
Gemba = A mindset
8D = A discipline

Thank you for your attention
Thank you for your attention

More ressources on :
http://gestionprojetauto.wordpress.com
Articles
Videos
Free templates
Favourite Automotive Links

Share this presentation

Available Trainings
Project Management
Problem Solving Methodology (8D)
Functional Analysis
Design FMEA (DFMEA)

Imad Tamir - イマヅ　タミル
Automotive Project Management : Training, Coaching
imad.tamir@gmail.com
(c) Copyright 2009-2010

http://gestionprojetauto.wordpress.com	57
http://www.slideshare.net	18
http://amirunnajah.blogspot.com	11

8D Problem Solving - Automotive Industry

by Gestion Projet Auto on May 30, 2010

Accessibility

Categories

Tags

Upload Details

Usage Rights

3 Embeds 86

Statistics

8D Problem Solving - Automotive Industry — Presentation Transcript