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8D Problem Solving - Automotive Industry
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Introduction to 8D problem solving methodology.
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8D Problem Solving - Automotive Industry
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
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Thank you for
your attention Thank you for your attention
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Videos
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Free templates
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Available Trainings Project
Management Problem Solving Methodology (8D) Functional Analysis Design FMEA (DFMEA)
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