The document discusses the 8D problem solving process for resolving issues permanently. It involves 8 steps - from establishing a team to analyze the problem, developing interim containment actions, determining the root cause, implementing permanent corrective actions, and preventing recurrence. The 8D approach ensures problems are solved completely through a structured methodology. This allows resources to then be used for improvement and innovation initiatives.

1. Corporate Quality - 8D problem
solving
TRAINING MODULE
CORPORATE QUALITY
SANDEN VIKAS INDIA LTD, FBD.
8 D PROBLEM SOLVING

2. Corporate Quality - 8D problem
solving
8 Discipline Problem Solving

3. Corporate Quality - 8D problem
solving
8 Discipline Problem Solving
Key Concept :
Resolve problems permanently so that they
never recur. This will allow you to work on
more “futuristic projects” such as process
/product improvement and other “forward
thinking” initiatives.

4. Corporate Quality - 8D problem
solving
Why Follow an 8-D Approach
• Problems need to be resolved “for good”.
• Problems usually re-surface with “Band Aid”
solutions.
• When problems are effectively resolved,
company can channel resources to more
strategic efforts such as innovation and other
“forward thinking” initiatives.

5. Corporate Quality - 8D problem
solving
Three Key Points of 8-D Problem Solving
• Determination of Root Cause
• Implementation of Permanent Corrective
Actions
• Systemic Actions to correct(improve) the
system as a whole. These actions could
involve the performance of FMEAs, Training,
Changing Standard Operating
Procedures……….

6. Corporate Quality - 8D problem
solving
Steps of 8-D Problem Solving Process
• D-0: The planning stage.
• D-1: Establishing the team.
• D-2: Describing the problem.
• D-3: Developing an Interim Containment
Action(ICA)
• D-4: Defining Root Cause and Identifying the Escape
Points ( 5 Why’s)
• D-5: Permanent Corrective Actions(PCA) for Root
Causes and Escape Point.
• D-6: Implementing the PCA
• D-7: Preventing Recurrence(Addressing the System)
• D-8: Recognizing the Efforts of the Team.

7. Corporate Quality - 8D problem
solving
D-0 : The Planning Stage
An 8-D is needed if:
Something has changed ( past performance exceeds
present performance) and there is a deviation from an
expected performance level.
Questions to Ask:
1. What has changed or what is the symptom?
2. Can the symptom be clearly described and
quantified?
3. Is any Emergency Response Action (ERA) required
to safeguard the customer?

8. Corporate Quality - 8D problem
solving
D-1 : Establish the Team
The team must have the required knowledge about the
process or system to be able to understand the problem
and have the potential to solve it in an allocated time
period.
Team Roles:
1. Champion (who owns the problem)
2. Leader
3. Members
4. Writer
5. Recorder
6.Time Manager/ Facilitator

9. Corporate Quality - 8D problem
solving
Obstacles that may arise
Obstacles that may be experienced by team:
1. Too many leaders
2. Roles not correctly defined
3. Time constraints
4. Lack of adequate communication
5. Lack of management support
6.Poorly defined objective
7.Lack of leadreship

10. Corporate Quality - 8D problem
solving
Team Objectives
• What needs to be accomplished( the end goal )
• How to get to the end goal

11. Corporate Quality - 8D problem
solving
D-2 : Description of the Problem
Step 1: What is Wrong with What ?
Step2: Develop a problem description
a. What is the problem ?
b. When did it happen ?
c. Where did it happen ?
d. How large is the problem ?
Step 3: Identify areas where more information is
needed
Step 4: Establish a set of boundaries around the
problem by asking the questions “What is” and
“What is not”

12. Corporate Quality - 8D problem
solving
D-3 : Develop an Interim Containment Action
Purpose of D-3:
To define, verify and implement an interim containment
action in order to isolate the effects of the problem from
affecting the customer (internal or external). The ICA
will remain in effect until a permanent corrective
actions has been implemented. D-3 must also validate
the effectiveness of the containment action.

13. Corporate Quality - 8D problem
solving
D-3 : Develop an Interim Containment Action
Rationale for D-3:
• To buy time until a permanent corrective action is
implemented.
• Protect the customer from the effect of the problem.
• Contain the problem from a cost, quality and
reputation perspective .

14. Corporate Quality - 8D problem
solving
D-4 : Define and Verify Root Cause
Purpose of D-4:
1. To isolate and verify root cause
2. To isolate and verify the location in the process
where the effect of the root cause could have been
detected but was not.

15. Corporate Quality - 8D problem
solving
D-5 : Choose and Verify PCA for Root cause
and Escape Point
Purpose of D-5 :
a. To select best PCA to remove root cause
b. to select the best PCA to address the escape point
c. Verify that both actions will be successful when
implemented
d. Verify that no other problems are created as a result
of the PCA selected
e. A time line for the PCA is defined.

16. Corporate Quality - 8D problem
solving
D-6 : Implement and Validate Permanent
Corrective Actions
Purpose of D-6 :
a. Plan and implement the PCA selected
b. Validate the PCA i.e. make sure it works
c. Remove the ICA(interim containment actions)
d. Monitor long term results
Note: You must have a method to validate the PCA
that has been implemented.

17. Corporate Quality - 8D problem
solving
D-7 : Prevent Recurrence
Purpose of D -7 :
a. Modify the existing systems (policies,
practices and procedures) in place so as to
prevent a recurrence of such a problem or
similar problems.
b. Make recommendations for systemic
improvements, if necessary.

18. Corporate Quality - 8D problem
solving
D- 8 : Recognition
Purpose of D - 8 :
To recognize and celebrate the success of the
team in resolving the problem by implementing
permanent corrective actions ( preventive in
nature) .

19. Corporate Quality - 8D problem
solving
Conclusions
• The 8 - D procedure involves a structured
thought process and emphasizes the
importance of a well documented report.
• 8- D Problem Solving encourages team work
in resolving problems.
• 8-D document is generated as the direct
consequence of a problem and therefore, it is
essential that the 8-D process be completed in
a structured and well thought out manner and
be meticulously documented .
• It has high internal and external visibility and
impact.

20. Corporate Quality - 8D problem
solving
Questions?