8D Problem solving – 8 Steps, when to use and how to make

Written By

Tiago Aparecido Rodrigues Rita

Developed by the Ford Motor Company during the 1960s and 1970s, 8D Problem Solving, is a tool that aims to effectively identify and address recurring problems. (also known as the “8 Disciplines for Problem Solving”).

It consists of a tool with 8 steps or disciplines to be followed to treat a problem so that it does not occur again.

The tool’s focus is to identify the root cause of the detected problem, plan a short-term fix (including immediate and containment actions) and actually implement a long-term solution (corrective actions) to prevent the problem from happening again in the future.

Over the years, the tool has evolved and in the 90s it gained another “D”: the “D0” that added an initial step in the tool and, as it is a predecessor discipline to the others, the name of the tool remained “8D”.

What all are the disciplines (or steps) of 8D

• D0 – Elaboration of a plan to solve the problem
• D1 – Building a team to work on the problem
• D2 – Description of the problem
• D3 – Development of an provisional plan to contain the problem
• D4 – Identification and elimination of the root cause of the problem
• D5 – Choice of actions and verification of the proposed solution
• D6 – Implementation of a permanent solution
• D7 – Prevention of the reappearance of the problem
• D8 – Celebrating the successful resolution of the problem with the team

When to use the 8D methodology?

8D is a consistent and easy-to-learn tool that, when applied correctly, brings numerous benefits to the organization in addition to effectively and systematically solving a problem that may be affecting the customer and consequently generating waste and inconvenience for both parties.

It is recommended to use 8D in critical situations where the problem is recurrent.

If the problem happens once in a while, or even if it’s just a recurrence of the problem, it’s worth looking at other troubleshooting tools that are simpler and less expensive.

The following are some examples of situations in which 8D is recommended:

• Frequent and recurring customer complaints
• Security or regulatory issues
• Unacceptable test failures
• Recurring waste problems
• Handling of non-conformities

How to make 8D?

Follow the following steps to Make 8D

Fact Finding (Step 0) :

1. Assess whether the problem really exists
2. Is there a deviation from what it should be?
3. Is the customer’s complaint valid?
4. Is the claim covered by the product’s warranty, or was it misused?

Step 1:

1. Assess who are the people in the company who can contribute to solving the problem (which areas should participate in the discussions?)
2. Team Formation

Step 2:

1. Problem Description
2. Characterize the problem
3. Get the first data about the problem (where/when/what?)
4. Translate the customer’s language into the company’s language
5. Understanding customer dissatisfaction, to bring it to the team

Step 3:

1. Immediate Actions / Containment
2. Discuss over time what can be done to minimize the effect of the problem
3. Take action so that the customer does not continue to receive products with the same problem
4. Looking for actions to contain the symptom of the problem (without knowing the cause)

Step 4:

1. Find Root Cause of the Problem
2. Determine the root cause of the problem (or causes), through the use of auxiliary tools and/or methods (Ishikawa / 5 Why / FTA / CEP / 5W 2H / etc)
3. Confirm of the root cause (or causes): Make sure that the team found the true cause(s) of the problem (Understand the failure mechanism / Seek to simulate the failure)
4. Define corrective actions: Look for actions that eliminate the cause(s), through understanding the failure mechanism.

Note : Support Tools or auxiliary tools to find the Root Cause of the Problem •Histogram • Pareto • Tendency Chart • Control Chart – CEP • 5W and 2H • Brainstorming • Affinity Diagram • Cause and Effect Diagram (Ishikawa) • The 5 Whys • FTA – Fault Tree Analysis • Process Mapping (SIPOC / Flowchart)

Step 5:

1. Proof of the Effectiveness of Corrective Actions
2. Evaluate each of the actions defined in Step 4, regarding their effectiveness in solving the problem
3. Seek to measure the impact of the corrective actions defined in Step 4, in relation to the resolution of the problem (if it is completely resolved / semi-minimized)
4. Perform small-scale tests and evaluate possible side effects.

Step 6:

1. Introduction of Corrective Actions
2. Definitely adopt the corrective actions that prove to be most effective in Step 5
3. Change the way of working / Make changes to the system /Standardizations
4. Make the changes official and from the date of implementation only work in this new way
5. Monitoring the Effectiveness of Actions
6. Remove Containment Actions (Step 3)

Step 7:

1. Preventive Actions Against Recidivism Discuss with the team what should be done to:
2. Do not allow the failure not to happen in the future (re-incidence)
3. Extend as elaborated in Step 6 to similar processes and/or locations that may present the same problem (prevention)
4. Transform actions into “best practices”
5. FMEA Review
6. Lessons Learned / Yokoten

Step 8:

1. Presentation of Results and Celebrating the successful resolution of the problem with the team
2. Present the actions taken and the results obtained, to the team, to ensure the learning of its members
3. Recognize the effort and dedication of the team (involve managers)
4. Approvals

8D and PDCA

The 8D follows the PDCA methodology. The table below shows the relationship between each 8D and the stages of the PDCA.

It is important to note that in disciplines from D0 to D5 there are some execution and verification points involved, for example, in discipline D3, a provisional plan is executed for the immediate containment of the problem and in discipline D5 it is verified whether the proposed solution would be effective in fact. to solve the problem.

However, the execution of the solution that will solve the problem is actually performed only in the D6 discipline as well as the verification and performance in the D7 and D8 disciplines.

Thank you. This is theoretical side of 8D for practical part click here.

Tiago Aparecido Rodrigues Rita @tiagorita

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