3. Project Objectives
To solve the defects occurring during assembly process of
Light commercial vehicles at H 3 Chassis line of Tata Motors.
It is part of efforts taken at Tata Motors H3 LCV Shop to
achieve World Class Quality Level 2.
4. 8D Methodology
8D stands for the 8 disciplines or the 8 critical steps for
solving problems
Isolates and contains the most basic causes of any
undesirable condition
Identifies the factors that contribute to the problem
Eliminates systemic factors that cause the condition
Focuses on the origin of the problem by determining its
root cause and Prevents problem recurrence
5. Eight Disciplines of Problem Solving
D1: Form a Team
D2: Define and describe the Problem
D3: Develop Interim Containment
D4: Determine Root Cause(s)
D5: Permanent Corrections for Problem
D6: Implement and Validate Corrective Actions
D7: Take Preventive Measures
D8: Congratulate Your Team
6. D1: Team formation
The team leader must generate a list defining the team
structure in order to ensure that a team was actually
formed for the 8D project
The team leader must schedule meetings periodically to
review progress of the 8D project and discuss action
Team members must complete their actions and report
back to the team leader
So, a team of four members was formed
7. D2: Describe the Problem
Describing the problem starts with a well-thought-out problem
statement. The problem statement should
Communicate the scope of the problem that the team is working on
and get the team focused.
Provide information relevant to the problem: data and information
on what the problem is and what the problem isn’t.
Determine root causes and implement or recommend a solution,
specify the deadline
8. D2: 5W 2H
Output of a process used to amplify the problem statement
in terms of 5W 2H
That is- Who, What, Why, Where, When, and How Big
(how much, how many, how often)
9. D3: Containment Actions
A containment means Actions those are taken to prevent the effect
of the problem or to prevent the full effect from impacting
customers
Quality alerts, purge and inspection, sorting bad parts from good
ones, adding short term operations, reviewing current procedures,
additional inspection and tests
Why is interim containment necessary?
11. D4: Develop Root Cause
Defining the root causes of a problem is the core of the 8D
problem-solving process
This is normally the toughest aspect of the problem-
solving process
Various tools are used for root cause analysis such as 5
Whys, Ishikawa diagram, etc.
12. D4: Ishikawa Diagram
Also known as Fishbone Diagram or Cause and Effect diagram
It classifies factors thought to be affecting characteristics
Associates these factors using arrows in a systematic and readily
understandable manner
This Provides an extremely good method for managing a large
number of factors in a single diagram
Determine probable causes from these
13. D4: To Prepare Cause and Effect Diagram
Various factors those affect the processes:
Man
Methods
Machines
Materials
Measurements
Environment
15. D4: Why- Why Analysis
The Why-Why analysis is an iterative question-asking
technique
To explore the cause-and-effect relationships underlying a
particular problem
The primary goal: To determine the root cause of a defect
or problem
Also known as 5 Whys
17. D5: Develop Permanent Corrective Actions
A systematic approach is needed to use the root cause analysis to develop a
solution
The solution should be:
Practical - The 8D team should be able to implement the solution
practically.
Feasible - The solution must be feasible.
Cost effective - Implementing and using the solution must be cost effective.
Robust - The solution shouldn’t fail when used in production.
18. D6: Implement Permanent Corrective Actions
Once the solution and its implementation are approved, the next step
is to create an Action Plan.
The Action Plan outlines what steps are needed to implement the
solution, who will do them, and when they will be completed.
19. D7: Prevent Re-occurrence
Preventing recurrence is an important part of a problem’s solution
To prevent recurrence of the problem, the team must verify that the
outcome of their Action Plan works and they must validate that the
outcome is on-target
Various tools such as FMEA, Control plans, One-point lesson etc.
are used
21. D8: Recognize the Team
Once a team has completed implementing the solution and ensured
that the solution works, all team members deserve to be
congratulated.
The organization (leadership group) shall recognize the team for
their efforts in a timely manner.
The project team shall recognize those that have provided the team
with support and assistance.
22. A PSR for AC pipe foul to Long. Member
Problem defining:
23. A PSR for AC pipe foul to Long. Member
Finding possible causes:
24. A PSR for AC pipe foul to Long. Member
Finding Root cause:
25. A PSR for AC pipe foul to Long. Member
Corrective actions:
26. A PSR for Baby Filter Mounting Bkt bend
Defining a problem:
27. A PSR for Baby Filter Mounting Bkt bend
Containment and Possible causes:
28. A PSR for Baby Filter Mounting Bkt bend
finding root cause:
29. A PSR for Baby Filter Mounting Bkt bend
Corrective measures:
30. Aftermath of Project
Problems were chosen based on their no. of occurrences & severity of problem.
Purging was done for these problems’ containment i.e. to avoid occurrence before the
permanent actions are taken.
Root cause is detected by following 8D methodology, using Why-Why analysis and
Ishikawa Diagram.
This method was used for 10 different problems. Follow up of all these Problem solving
report was done by checking the status of all the defects.
31. Following table gives overview of all the defects, their root cause, and actions taken to solve:
Sr.
No.
Defect Root Cause Proposed Solution Vehicle
Problem Status
(On 15 Dec 2015)
1 AC Pipe foul to Long
Member
Improper clamping process
of AC Pipe fitment
Bracket hole on which pipe is
mounted is changed
810/38
LPT
Closed/ No
reoccurrence
2 Baby Filter Mounting
Bracket bent
Wrong mounting bracket in
used
Correct bracket is to be used
for mounting
Ultra
1012
Closed/ No
reoccurrence
3 Brake Chamber Stud
Washer Damaged
Incorrect procedure
followed
Operator be instructed to
remove plastic cap before
tightening
Y1 Bus Closed/ No
reoccurrence
4 Brake pipe and Rear
brake foul
Operator Unaware About
correct procedure
Operator was instructed to
follow correct procedure
Ultra
1012
Implemented,
No reoccurrence
5 AC pipe foul to Long
Member
Insufficient clamping of AC
Pipe
Clamping Bracket Changed Ultra
1012
Closed/ No
reoccurrence
32. Sr.
No. Defect Root Cause Proposed Solution Vehicle
Problem Status
(On 15 Dec 2015)
6 Propeller shaft offset
and Foul with centre
bearing
During inversion propeller
shaft Shifts and fouls
Centre bearing bracket be tilt
& adjusted so as to avoid
Offset and fouling
Ultra
1012
Implemented,
No reoccurrence
7 Gear lever cable
broken
Gear lever cable clamping
not done
‘P’ clamp is used on ‘L’ Bkt
To clamp gear lever
Y1 Bus Closed/No
reoccurrence
8 Silencer rubber
dislodged
Silencer mounting hook
fixture Faulty at supplier end
Silencer hook fixture to be
corrected at supplier’s end
909/27
LPK
Closed/No
reoccurrence
9 Cable connector not
parked
Operator unaware about
correct process
Checking started and operator
trained
407
LPT
Implemented,
No reoccurrence
10 Coolant Leakage
from Auxiliary tank
Fitment valve threading
mismatch
Ana-Bond should be started in
use for perfect tightening
Ultra
1012
Implemented,
No reoccurrence
Following table gives overview of all the defects, their root cause, and actions taken to solve (contd.):
33. Conclusion
8D Methodology was designed to solve various problem solving using various quality
tools. These tools include 5W 2H, Why-Why analysis, Ishikawa diagram, Brainstorming,
etc.
Vehicles should be checked for the effectiveness of solution for 20 days for the defects and
if no reoccurrence of these defects arise, then defect is closed.
6 Such defects were closed and 4 Proposed & implemented solutions showed no
reoccurrence (till 15 Dec 2015). These defects solved will help Tata Motors achieve WCQ
level 2.
So it can be established that 8D methodology using Why-Why analysis and Ishikawa
Diagram is an effective way to solve defects in a vehicle assembly process.
