SOP For 8D Method for problem solving

1) Scope
Scope of 8D methodology problem solving procedure is to guide user to focus on origin of the problem occurs in between melting to dispatch by
determining root cause of problems and establishing permanent corrective action to solve the problem with systematic approach of 8 steps.

2) Purpose
1.To use 8d approach to solve critical problems in production process by finding out root cause and all potential causes.

2. To continuously improve the effectiveness and efficiency of problem solving of team.

3.To improve the skills of team related to effective implementation of corrective and preventive actions.

4.To get better understanding of how to use basic statistical tools for problem solving

5. To get in-depth understanding related to changes required in system.

3) When to use 8d (Triggering Mechanism)

Sr. NO. Problem Description 8D

Problem arises for characteristics related to safety, regulatory, special

1 Use 8D methodology
(functionally impact)

2 Complaint received from customer ( Internal, External) Use 8D methodology

Poor quality performance and rework, rejection, scrap, waste at

3 Use 8D methodology
unacceptable limits.

4 Warranty concern raised from customer end. Use 8D methodology

4) How to use 8D:

Step 1: DO Plan (Prepare and plan for 8D

1) Define the problem and verify the problem whether it's repeated or new one.

2) Describe the location of the problem.

3) Describe the component data (Quantity, part name etc.) related to the problem.

4) Also provide the disposition detail related to the component, either it's rework or reject.

Step 2: D1 Form team ( Establish CFT team)

Form the team covering Champion, Leader, CFT member and SME (Subject matter experts). For responsibilities, kindly refer following 8D
responsibility matrix.

8D Team Responcibilies Matrix

Sr. NO. Team Member Team member responsibilities

Champion is the person who is responsible for approval of changes come out
1 Champion from 8d process and implementation of those changes.

1. Leader is the person who knows 8D methodology will lead the team through
8D process. (It's not required that the leader should had knowledge related to the
2 Leader problem they are solving).
2. Responsible for distribution of role and responsibilities.

CFT Member (Core team 1.Core team should involve people related to product, process and data.
3
member) 2. CFT member should have product application based knowledge.

SME is optional. It's responsible for data collection, planning, brainstorming,

4 Subject matter expert (SME) analysis etc.

Step 3: D3 Problem description ( Describe the problem)

1.Leader should describe the problem with the help of tools like 5W25, affinity diagram, fishbone diagram, Is/Is not (Inductive tool).

2.Leader will be solely responsible for problem description and communicating it with the team.

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 Step 4: D3 Containment action
1) Use PDCA approach for planning containment actions.

Plan: Prepare containment action plan including implementation activities such as resource management, resource planning and equipment
planning etc.
Do: After preparation of plan to execute all containment action, ensure that the actions should be clearly communicated at processes and
management levels to all process owners.
Check: CFT must ensure that all containment actions are implemented exactly on respective process and ensure that it continue to be effective.
CFT also ensure that there is cons of the containment actions.

ACT: CFT must ensure that all containment actions are take, no actions are missed/ pending. For this CFT can use questionary.

Step 5: D4 Root Cause Analysis

1. Use cause and effect diagram to list out all potential Causes of the problem.

2. Analyze all potential causes to find out actual root cause of the problem.

3. For root cause analysis, leader should use tool Why why to get into actual root cause of the problem. You can use tools like pareto, flow chart,
fishbone etc. as per requirements.

4. Verify the root cause of process through data collection.

5. Verify the process flow diagram to determine actual location of root cause in process.

Step 6: D5 Corrective actions

1. CFT list out all corrective actions need to implement on shop floor and study all effect (cost ) etc. while implementing it, Verify the corrective
actions feasible or not.

Step 7: D6 Implementation and validation

1. CFT list out all corrective actions need to implement on shop floor with responsibility given to the team member of CFT and set the target
dates.

2.Validate the results obtain from successful implementation of permanent corrective actions with the help of measurements.

Step 8: D7 Prevent recurrence and document updation

1.Review the similar product and process for problem prevention.

2.Identify all preventive action and implement preventive action on respective process.

3.For system prevention, update the system documents like control plan, fmea, Work instruction, SOP, Drawing etc.

Step 9: D8 Prevent recurrence and document updation

1. Verify the results come after successful implementation of solution implemented through 8D.

2. Verify the 8D report is completed , all related documents updated and share with team. If any 4M changeges done to solve the problem, kindly
monitor the effectiveness and update the required document ( PFD, PFMEA, Control Plan, Work istruction, SOP).

3.Verify if specific team member had significant contribution in problem solving. Recognize those efforts.

4.Do meeting with the team to discuss learning gain from this 8D. (Note: Please refer doc. No. F:CQ:72 for filling 8D report.)

6) Responsibility

Respective process quality engineer are fully responsible for effective working of the system. All process owners are responsible for successful
implementation of actions.

7) Safety
Safety Shoes, Apron and Hand gloves are compulsory while doing ganba visit during 8D

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