Eight Disciplines Problem Solving

Eight Disciplines Problem Solving is a method used to approach and to resolve problems - typically employed by quality engineers or other professionals. Also know as 8D, 8-D Problem Solving, G8D or Global 8D.

8 Steps of Problem Solving in Engineering

D1: Assemble a cross-functional team of experts

D2: Define the Problem fully

D3: Implement and verify Interim Containment Actions (ICAs) as needed. Also known as Temporary Fixes.

D4: Identify and Verify Root Cause

D5: Choose and verify Permanent Corrective Actions (PCAs). Preventive Actions are also chosen.

D6: Implement and validate PCAs

D7: Prevent recurrence of the Problem/Root Cause

D8: Recognize the efforts of the Team

History

The U.S. Government first standardized the 8D process during the Second World War, referring to it as Military Standard 1520: “Corrective action and disposition system for nonconforming material”.

It was later popularized by the Ford Motor Company in the 1960’s and 1970’s. 8D has become a standard in the Auto, Assembly and other industries that require a thorough structured problem solving process.

The 8D Problem Solving Process is used to identify, correct and eliminate problems.The methodology is useful in product and process improvement. It establishes a standard practice, with an emphasis on facts. It focuses on the origin of the problem by determining Root Cause.

Usage

Many common disciplines are typically involved in the "8D" process, all of which can be found in various textbooks and reference materials used by Quality Assurance professionals. For example, an "Is/Is Not" worksheet is a common tool employed at D2, and a "Fishbone Diagram" or "5 Why Analysis" are common tools employed at D4.

The 8D process originally arose out of Ford Motor Company, where it went through several iterations over several decades, including "TOPS" or "Team Oriented Problem Solving". In the late 1990's, Ford developed a revised version of the 8D process, officially titled "Global 8D" (G8D) which is the current global standard for Ford and many other companies in the automotive supply chain. The major revisions to the process are as follows:

* Addition of a D0 (D-Zero) step as a gateway to the process. At D0, the team documents the symptoms that initiated the effort along with any Emergency Response Actions (ERAs) that were taken before formal initiation of the G8D. D0 also incorporates standard assessing questions meant to determine whether a full G8D is required. The assessing questions are meant to ensure that in a world of limited problem-solving resources, the efforts required for a full team-based problem-solving effort are limited to those problems that warrant these resources.

* Addition of Escape Point to D4 through D6. The idea here is to consider not only the Root Cause of a problem, but equally importantly, what went wrong with the control system in allowing this problem to escape. Global 8D requires the team to identify and verify this Escape Point (defined as the earliest control point in the control system following the Root Cause that should have detected the problem but failed to do so) at D4. Then, through D5 and D6, the process requires the team to choose, verify, implement, and validate Permanent Corrective Actions to address the Escape Point.

Along with these revisions to the process, Ford developed a web-based software package, called Global 8D, to facilitate implementation of this process, standardize reporting, maintain a searchable repository of problem-solving efforts, and enhance team collaboration. Presently, this software is only available within Ford, although plain 8D Software is available to the public from other companies.

Recently, the 8D process has been employed extensively outside the auto industry. As part of Lean initiatives, it is used within Food Manufacturing, High Tech and Health Care industries.

ee also

* Quality management system (QMS)
* Corrective and Preventative Action (CAPA)

External links

* [http://www.siliconfareast.com/8D.htm The 8 Disciplines (8D) Process]
* Laurie Rambaud (2006), "8D Structured Problem Solving: A Guide to Creating High Quality 8D Reports", [http://www.phredsolutions.com PHRED Solutions,] ISBN 097905530X