Table of ContentsThe 8-D Methodology
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Origins: Mil-Std 1520 The Target & Goal The 8-D System Typical Investigation Time Line A Nonconformance Database Analysis vs. Action Process Tools Process Tools Recommended Statistical Courses Statistical Tools Statistical Tools 1 Statistical Tools 2 Universe, Populations & Samples . Interpreting Statistics Interpreting Statistics Interpreting Statistics Histogram Animation Normal Distribution (Bell Curve) Standard Deviation - A Measure of Dispersion Basic Terms Standard Deviation Cp Animation Cpk Animation D0 - Problem Identified Where Was The Problem Identified? Typical Top Level Operations Flowchart Process Flow Animation Early Process Flow Diagram Where Was The Problem Discovered? Where Did The Problem Escape? White Space Issues Asking Why. How Far? Where Do I Look? Design Block Diagram Example Cause and Effects Animation Failure Modes In Measurement Systems Process Variation Distributions From Variation Process Variation Causes of Variation Facts About Causes of Variation Tampering - Process Variation Structural Variation Problem vs. Symptom When An 8-D Is Necessary When An 8-D Is Necessary When An 8-D Is Necessary Verification vs. Validation Investigative Questions Investigative Questions D1 - Use Team Approach The 8-D System Team Approach Establishing A Team (Flow) The Team - Basics Brainstorming How To Brainstorm Individual vs. Group Brainstorming Define Scope Of Team Natural Work Group vs. Team Team Structure Team Organization Decision Making Criteria / Model Roles In A Team Inputs To Team Team Goals Basic Team Rules Team Meeting Responsibility Team-to-Team Communication Successful Teams Team Check List D2 - Describe The Problem The 8-D System Describe the Problem Describe the Problem Customer Complaints Operational Definition of the Problem Symptoms vs. Causes Problem Solving In-Depth Analysis 5W - 2H Analysis 5W - 2H Analysis Stratification Analysis Describe the Problem Describe the Problem Flow Root Cause Analysis Investigative / Tracking Charts Is / Is Not Questions Is / Is Not Example Timing Plan Describe the Problem Phases Describe the Problem Questions Describe the Problem - 5W-2H Customer Terms / Symptoms Understanding Your Processes and Systems Production Cause and Effects Diagram Service Cause and Effects Diagram Flow Charting Creating a Process Flow Chart Creating a Process Flow Chart Early Process Flow Diagram GM Example Process Flow Chart Basic Flow Chart Example Basic Flow Chart Example Control Plan Example (GM) FMEAs - Predicting Failure & Problems Describe The Problem Check List D3 - Containment The 8-D System Implement and Verify - Interim (Containment) Actions Contain Symptom Flow Containment Actions Objective Containment Actions Containment Actions Containment Actions Typical 8-D Time Line Containment Actions Containment Actions Flow Verifying Containment Actions - Pilot Runs Containment Actions Verification Questions Contain Symptom Check List D4 - Define Root Cause(s) The 8-D System Define and Verify Root Cause(s) Root Cause Of A Failure Two Root Causes Initial Data Evaluation Initial Data Evaluation Initial Data Evaluation Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Interpreting Control Charts Control Chart Analysis Reaction Control Chart Analysis Reaction Define and Verify Root Cause(s) Define and Verify Root Cause(s) Define and Verify Root Cause(s) Define and Verify Root Cause(s) Hypothesis Generation Six Steps Of Investigation Define and Verify Root Cause(s) Define and Verify Root Cause(s) Identify Alternate Solutions Define and Verify Root Cause(s) Define and Verify Root Cause(s) Define and Verify Root Cause(s) Identify Potential Causes - Cause & Effects Diagram Analyze Potential Causes - Validate Root Cause Potential Causes - Some Questions Analyze What Has Changed Data and Root Causes Product - Process Assumptions Errors 1 Errors 2 Errors 3 Process Failure Causes Process Control Examples The Poka-Yoke System We have Quality Problems! We Have a Quality Problem! Section One Poka Yoke Defined Process vs. Operation Operation & Process Categories of the Process Function Categories of the Operation Function 5 Elements of Production Defining The 5 Elements Changes in the Elements 4 Process Phenomena's Shigeo Shingo's Five Questions Section Two Reasons Why We Don't Need Poka Yoke Separating Error From Defect Causes of Defects Levels of Defects Section Three Inspection Philosophies 3 Methods of Inspection Judgment Inspection SPC Inspection Source & Sequential Inspection Section Four Production Efficiency & Waste Types of Waste Cost Contributing to Waste Section 5 Shingo's Method Poka Yoke Devices, Systems & Inspection Poka Yoke Devices, Systems & Inspection Every Day Examples Electrical Polarity Poka Yokes Floppy Disk Poke-Yokes Poka Yoke Devices, Systems & Inspection Section 6 Organizing Systems for Zero Defects Questions to Ask About Present Systems D5 - Choose, Implement & Verify Corrective Actions The 8-D System Choose, Implement & Verify CA Objective Choose, Implement & Verify Corrective Actions Choose, Implement & Verify Corrective Actions Choose, Implement & Verify Corrective Actions Choose, Implement & Verify Corrective Actions Choose, Implement & Verify Corrective Actions Confirmation Questions Verification Questions Corrective Actions Check List D6 - Implement Permanent Corrective Actions The 8-D System Implement Permanent CA Objective Implement Permanent Corrective Actions Implement Permanent Corrective Actions Implement Permanent Corrective Actions Implement Permanent Corrective Actions Flow Implement Permanent Corrective Actions Flow Validation Evidence Corrective Action Questions Ongoing Controls - Questions Forecast Outcome Implement CA and Verify Over Time Check List D7 - Prevent Recurrence The 8-D System Prevent Recurrence Objective Prevent Recurrence Prevent Recurrence Prevent Recurrence Prevent Recurrence Prevent Recurrence Flow Prevent Recurrence Questions Prevent System Problems Check List D8 - Congratulate Your Team The 8-D System Congratulate the Team Congratulate Your Team Congratulate Your Team Congratulate Your Team Flow Congratulate Your Team Objective & Questions Congratulate Your Team Check List
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