| The 8-D Methodology |
| Files Included In This Package |
| The Red Road Graphics |
| About .swf Files - 1 |
| About .swf Files - 2 |
| Don’t Let This Happen To YOU! |
| 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 |