Eight Disciplines Problem Solving is a method used to approach and to resolve problems, typically employed by quality engineers or other

professionals. D0: The Planning Phase: Plan for solving the problem and determine the prerequisites. D1: Use a Team: Establish a team of people with product/process knowledge. D2: Define and describe the Problem: Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how and how many (5W2H) for the problem. D3: Developing Interim Containment Plan Implement and verify Interim Actions: Define and implement containment actions to isolate the problem from any customer. D4: Determine and Identify and Verify Root Causes and escape points: Identify all potential causes that could explain why the problem occurred. Also identify why the problem has not been noticed at the time it occurred. All causes shall be verified or proved, not determined by fuzzy brainstorming. D5: Choose and verify Permanent Corrective Actions (PCAs) for root cause and Escape point : Through pre-production programs quantitatively confirm that the selected corrective actions will resolve the problem for the customer. D6: Implement and validate PCAs: Define and Implement the best corrective actions. D7: Prevent recurrence: Modify the management systems, operation systems, practices and procedures to prevent recurrence of this and all similar problems. D8: Congratulate your Team: Recognize the collective efforts of the team. The team needs to be formally thanked by the organization.[1][2] 8D has become a standard in the Auto, Assembly and other industries that require a thorough structured problem solving process using a team approach. www.johnwoodruffe.co.uk

PROBLEM SOLVING 8D SUMMARY SHEET

DATE AREA REPORTED

REF:
D0 D1 SKETCH RESPONSIBLE SUPERVISOR

DEFINE

DEFINE RESPONSIBLE GROUP

CLARIFY THE PROBLEM

( How many / which body spec. / which area on body / first no good/ tendency on other bodies etc )

APPROPRIATE STANDARD

D2

SKETCH

DETECTION PROCESS NAME MEASURE POINT OF DETECTION

D3

QPS NUMBER

ACTION CONTAINMENT

SEQUENCE / BODY NUMBER (Date / Time)

CHECK CONTAINMENT

D4 ALWAYS CONFIRM STANDARDISED WORK ADHERENCE

DIRECT CAUSE

MAT

MAN
WHY

EFFECT

WHY

WHY POSSIBLE CAUSES POSSIBLE CAUSES ANALYSE

WHY

EQUIP

METHOD

WHY

INVESTIGATE MOST LIKELY OK NG REASON

ROOT CAUSE

1. 2. STANDARDISED WORK ADHERENCE DIRECT CAUSE =

TO STOP THE CAUSE COUNTERMEASURE

QPS CHANGES

WHO

WHEN

CHECK

D5 D6

IMPROVE

.
TO DETECT IT EARLIER CHECK

.
SHIFTS AGREE PAPERWORK CHANGES OPERATORS RETRAINED

.
D7

SHARE / FURTHER COUNTERMEASURE

REPEAT PREVENTION

CONTROL

TEAM

D8

PROBLEM SOLVING 8D SUMMARY SHEET

DATE

REF:

4000/67118/2
D0 D1

23.3.02

AREA REPORTED

FCPA
SKETCH RESPONSIBLE SUPERVISOR

DEFINE

DEFINE

Rattle From lH Door Interior (Front Door) - Back Portion Close to lock

RESPONSIBLE GROUP

Door line
Range
# 67112 0 # 69998 +1 DAY * OK +2 DAY OK

Bill Friday
DOOR INNER
SKETCH D2

CLARIFY THE PROBLEM

( How many / which body spec. / which area on body / first no good/ tendency on other bodies etc )

APPROPRIATE STANDARD

Door Closing Noise (N/G)

20 15 10 5 LHF

VIS: 318 / 2
+3 DAY OK

14

NO AUDIBLE NOISE

RHF LHF RHF

100 Vehicles Checked (John Smith )

LOCK MECHANISM

14X NG

* 1st N/G Vehicle 67000

DETECTION PROCESS NAME

BURR HOLDS OFF FIXING CONTACT CAUSES NOISE

D3

MEASURE

POINT OF DETECTION

* NOISE DOOR LINE INSP STN II SHIPPING * 1ST DOOR SHUT

DOOR SHELL

(OK)

INPSECTION PROCESS STN II

QPS NUMBER

(OK)

(OK)

N/G

DL 23108
SEQUENCE / BODY NUMBER (Date / Time)

ACTION CONTAINMENT

1. ADDITIONAL CHECK (+1 OPERATOR) INSPECTION STN II FITTING ADDITIONAL FOAM PAD TO REPAIR (# 67184) 2. INVESTIGATE DOOR LINE FIT PROCESS + REPORT
ALWAYS CONFIRM STANDARDISED WORK ADHERENCE

67184
CHECK CONTAINMENT

24/3 25/3 27/3 01/4 04/4

D4

DIRECT CAUSE

MAT
REGULATOR BAR GLASS SPECIFICATION

MAN
NO FIT OF FOAM PAD NEW OPERATOR
EFFECT WHY WHY

Regulator bar touching door beam Bar is out of position Top fitting is loose Hole has burr holding off fixing
WHY

RATTLE
POSSIBLE CAUSES

Trim
WHY POSSIBLE CAUSES

ANALYSE

TORQUE SETTING NG LOCK BOLTS

CONNECT BAR SEQUENCE

LOCK FIT SEQUENCE

EQUIP

METHOD

Press
WHY

Poor Punching from Press Shop Punch is worn

INVESTIGATE MOST LIKELY OK NG REASON

ROOT CAUSE

1. 2.

Torque Setting lock Join Bar Touching Door Outer

STANDARDISED WORK ADHERENCE

OK NG OK

100 VEH CHECKED STRIP DOWN N/G VEHICLE

REGULATOR BAR TOUCHING DOOR BEAM

Worn Punch on Part #53811 (No Standard check prior to run) (No Maintenance Schedule in place)

DIRECT CAUSE =

TO STOP THE CAUSE COUNTERMEASURE

QPS CHANGES

WHO

WHEN

CHECK

Punch Type H34 Added to 3 monthly maintenance Schedule

TO DETECT IT EARLIER

IMPROVE

MAINT SHEET H34 UPDATED H34 /QPS/2

D5 D6

Is

28.3.02
29/3 29/429/5 29/6 29/7
CHECK

ADDED TO PANEL CHECKSHEET k34/QPS/2 CHECK FOR NO BURR IDENTIFIED AS QUALITY KEY POINT
PAPERWORK CHANGES OPERATORS RETRAINED

Is

28.3.02

. 29/5 . 29/6 29/7 29/3 29/4

D7

SHIFTS AGREE REPEAT PREVENTION CONTROL

SHARE / FURTHER COUNTERMEASURE

JB 28.3.02 PH 29.3.02

AS ABOVE SHEETS SIGNED ON REVERSE BY OPERATORS S MIN BRIEF 1.4.02

TH PT

PS JB QV SB PF JT

28.3 29.3

CHECK ALL DIES FOR PUNCH TYPE K34 STUDY + CONSIDER ALL PM CHANGE TO 3 MONTH PT BY 10.4.02
D8

TEAM

AS

PT

JB