8D Problem Solving
Duration: 2 days
8D problem solving course is a 2 days session that will provide participants with an
understanding of a discipline structured problem-solving methodology for product or
process improvement.
One of the key objectives of 8D problem solving method is to ensure that the root cause
is identified and permanent actions are taken to prevent future re-occurrence.
This course is targeted at newcomers, engineers, supervisors, technicians, managers and
senior leaders. During this course, the participants will learn the 8 important steps of the
problem solving methodology.
Participants will learn how to look into root causes using the various tools like Cause &
Effect, Why-Why Analysis, Non Conformance vs Detection vs Systemic Root cause &
Fault Tree Analysis. Participants will also learn other problem solving technique in
identifying potential corrective actions, Poka-Yoke Solution and methods for verification,
implementation of permanent corrective actions and validation. Equally important step
of prevention actions will be taught to ensure no recurrence of similar problem.
8-D Method Course content:
Day Time Training content
1 Introduction to 8D
1. Introduction
2. General description and application of 8D
3. History of 8D
4. The Need for 8D method
D0 – Preapre for the 8D Process
Identify & quantify Problem/Symptom
Decision on forming 8D team
D1 – Establish a Team
Barriers to Teamwork
4 phases of team development
Who are the stakeholders & SMEs
How to ensure effectiveness of 8D teams
Exercise 1.
D2 – Describe the Problem
Scope of the problem
Is & Is Not Methodology
Quantification of problem: Continuous vs Attribute
Various techniques for complete problem description
Checklist for problem description
Exercise 2
D3 – Develop Interim Containment Action
What is containment actions
Considerations for containment actions
Various forms of containment actions
Verification vs Validation
Checklist for containment actions
Exercise 3
Day Time Training content
2 D4 – Define & Verify Root Cause & Escape Point
Symptom versus root cause
Data collection Tools
Root Cause Analysis – 5 Why Tool
Non conformance, Detection & Systemic Root cause
Fault Tree Analysis
Concentration Diagram
Cause & Effect Diagram
Cause & Effect Matrix
Root Cause Verification
Escape Cause
Exercise 4
D5 – Choose & Verify Permanent Corrective Actions for Root Cause and
Escape Point
Development of possible solutions
Poka Yoke (Mistake Proofing)
Six Thinking Hats
Creative Thinking
Brainstorming
Affinity Diagram
Solutions Selection Matrix
Choose & Verify solutions
Exercise 5
D6 – Implement & Validate Permanent Corrective Actions
Communication & Approvals
Timeline and Action Plan
Training consideration
Validation of results
Exercise 6
Day Time Training content
D7 – Prevent Recurrence
Update Operating Procedures
Checklist for preventing recurrence
Finalize 8D report
Lesson Learn & Knowledge Sharing
Exercise 7
D8 – Recognize team and individual contributions
Recognition versus Reward
Various forms of recognition
Closure.
Note:
Due to the very interactive nature of the workshop, the trainer may make minor changes
to the sequence of topics listed above or the topic itself during the workshop to ensure
participants are able to maximize their learning.
Course language
Main medium of instruction is in English.
