What is the 8D problem-solving process?
8D problem-solving process
The 8D problem solving process provides a simple framework to help correct product and process problems. The tool is made up of eight ordered steps, each step clearly guiding teams on what to do and when to do it. It is the generic problem-solving tool used across many industries, particularly automotive and aerospace.
The 8D process incorporates all of the key aspects of problem-solving management:
- Problem description and reporting
- Stakeholder and SME management
- Containment of the problem
- Establish the facts
- Root cause analysis
- Problem correction
- Problem prevention
- Reporting and recognition
When the 8D process has been completed and recorded, the result is a report showing the 'how' and 'why' a solution was arrived at. Some organizations will demand detailed Corrective Action reports from their suppliers if an issue is found with a supplied product or service, for example.
8D(8 disciplines) workflow
Discipline 0 (D0): Summary
It's important to name the 8D investigation to identify it easily and quickly.
Next, a short statement to summarise the problem should be defined:
- Describe what is effected
- Describe the symptoms
- Identify potential consequences and impact
Be clear and factual. Try to avoid feelings or non-facts here.
Discipline 1 (D1): Form the team
The first step of the 8D process is to form a team of interested parties. At the beginning of this process, this may only be the person responsible for managing the 8D investigation. This team should change and grow as the investigation moves forward.
The team should be cross-functional and should include the process owner and other key stakeholders:
- Subject matter experts(SME's)
- Process owners
- Customer and suppliers
Discipline 2 (D2): Describe the problem
This step involves a detailed assessment of the problem. Record all relevant information, and be clear and objective. Consider including the following details:
- Identity of the customer
- Identity all known facts
- When, who, what
- It is/it is not lists
Discipline 3 (D3): Interim containment actions
Define the immediate actions required to prevent the situation from getting worse. Containment actions are usually short-term and may be costly. Sometimes, no containment is necessary. Examples include:
- Notifications and communications
- Concessions and permits
- Extra product checks
Discipline 4 (D4): Root cause analysis
Perform failure analysis and investigations to determine the root cause of the problem. Keep records of all root cause analysis that have been conducted.
Root cause analysis tools should be selected to match the problem being worked. Every problem is different, here are some common tools:
- Fishbone (Ishikawa) diagram
- 5-Why
- Root cause statement
Discipline 5 (D5): Permanent corrective actions
Identify all possible corrective actions to address the root cause of the problem. Use brainstorming techniques like Six Hats and Random Word if required. Provide a rationale for each proposed corrective action.
Grade proposed solutions for cost and suitability. Perform FMEAs as required to help identify pitfalls and risks:
- List all possible solutions
- Identify the best solutions
- Calculate the risk of making changes using FMEA
Design an implementation plan for the changes required to correct the root causes. Propose completion dates and allocate owners of tasks.
Discipline 6 (D6): Implement and validate
Deploy changes and monitor effectiveness. Data showing that the corrective actions performance should be captured and referenced here:
Discipline 7 (D7): Prevent recurrence
Actions necessary to prevent the same problem from arising again are defined here. Consider the following:
- Update procedures and policy
- Update standards
- Improve KPIs
Consider applying the changes to other products or processes.
Discipline 8 (D8): Closure and team celebration
The last step of the 8D problem-solving process is to congratulate the team and publicize success:
- Summarize the investigation
- Lessons learned
- Publicize success
Things to consider
- Think about using professional 8D software
- Make 8D your primary method of corrective action management and reporting
- 8D is an effective tool for managing product problems, process issues, and other opportunities for improvement.