This is one of a problem solving method .

1. FARSHID HESAMI
FARSHID HESAMI
Email Address : farshidhesami@gmail.com
BIW EXPERT ENGINEER
https://www.linkedin.com/in/farshid-hesami-33a09529/
Cellphone : +989123387563

2. FARSHID HESAMI
“Describe a time when you led a team in solving a problem within Manufacturing. What tools/techniques
did you use and how did you ensure the team worked well?”
Presentation Question :

3. FARSHID HESAMI
After a problem occured either in a manufacturing Plant or in the Field, it is most important for engineer to have a
clear understanding of the problem.Therefore a detailed reporting is essential.
In fact that Company is not focused on a single way,certain problem solving / reporting methods are qualified,
such as :
Answer :
What tools/techniques……
 8D Report
 Six Sigma
 Ishikawa
 A3 (used with Toyota )
 5Phase (used with GM)
 7Step (used with Chrysler)
 PDCA (Plan, Do, Check, Act)
 PDSA (Plan, Do, Study, Act)
 Fault Tree Analysis (FTA)
problem solving methods:

4. FARSHID HESAMI
Causal analysis and
problem resolution
8D Report (Ford)
5Phase (GM)
7Step (Chrysler) My Answer is 8D method

5. FARSHID HESAMI
Why 8D?
More Solid & Comprehensive than the others.
The most popular one been applied in the field.
Provide a guidance by Systematic Approach in Problem Solving.
8D is a problem-solving methodology for product and process problems.

6. FARSHID HESAMI
The effective implementation of the 8D :
Reliability.
Design verification, product and process validation.
Potential failure mode and consequence analysis (FMEA(
Production parts approval process (PPAP(.
Statistical process control (SPC).

7. FARSHID HESAMI
8D benefits :
Properly completing the 8D process, in addition to identifying the
ROOT CAUSE
For suppliers .
For Customer .
8D benefits :

8. FARSHID HESAMI
Q : How ensure the team worked well ?
A : Teamwork problem solving
Skills
 More talents
 More experience
 More knowledge
 More technical competence
Communication
 Cross departmental lines
 Increase productivity
 Increase dignity morale
Participation
 Consensus decision-making
 Buy in‘‘ to change
 Job enrichment
Effectiveness
 Better solution
 Solutions more likely to be accept
 Response to complete stated mission

9. FARSHID HESAMI
•8D – Report ( the 8 disciplines(
D1 – Select the Team
D2 – Describe the Problem
D3 – Implement and verify
containment actions
D4 – Define and verify Root Cause(s)
Identify potential Causes
Select most likely Causes
Is the potential
Cause a Root Cause ?
Identify possible
Corrective Actions
yes
no
D6 – Implement permanent
Corrective Actions
D8 – Congratulate the Team
D7 – Prevent Recurrence
D5 – Verify Corrective Actions

10. FARSHID HESAMI
Problem of missing a hole in Front bumper
Problem description :
Front modules frame missing a hole
Part Name :
Front bumper Reinforcement
Supplier name :
xxxxxxx
Date of complaint :
2017/04/12 / Night
Complaint source:
Production Line 20
Total defect quantity:
305 / Batch Kw50
Defect type:
Missing a hole

11. FARSHID HESAMI
Root cause fishbone :
Materials
Method/Progress
Environment
Q-Defect
Man
 Is there inspection system ?
 Is there no implementation of the
Inspection?
 Is staff turnover?
Machine
 Is the product raw materials will
Affected this issue?
 Is there a test capability for this
Hole?
Measurement
 Is the devicenis abnormal?  Does the production environment
causing this problem?
 Is there a error proofing?
 Are there inspection requirments
for this hole?
 Is there equipment maintenance
requirments?
 Implementation of the system
whether the monitor?

12. FARSHID HESAMI
Root process confirmation :
Man : execution
Man problems.............
Employees failed to implemant
requirments for product sampling.
Employees Don't perform inspection of the
equipment maintenance system.
Machine : Model quality
Machine problems.............
Punch fracture,it should confirm the status
of the punch material(To be confirmed).
Method :Proofing and Monitor
Method problems.............
There is no error proofing in
the welding fixture

13. FARSHID HESAMI
Action execution :
Before
 There is no error proofing in the
welding fixture
After
 Increase errorproofing pin on the
welding fixture.

14. FARSHID HESAMI
Prevention of system action :
Prevention of system action Execution date Remark
Fixture error proofing .
A test focused on labeling requirements .
Mold punches state investigation .
2017/04/12
2017/04/12
2017/04/12
Compleated
Compleated
Compleated

15. FARSHID HESAMI
THE END