8D Problem Solving Methodology

Eight Disciplines Problem Solving (8D) is a method used to approach and to resolve problems. Its purpose is to identify, correct and eliminate recurring problems. It comprised of 8 stages or discipline with initial planning stage. The disciplines are:

 Discipline 0: Before you begin to make a team to resolve the problem, you need to plan your approach, and determine the prerequisites.

 Discipline 1: Define a cross-functional team

            The first step in 8D methodology is to establish a cross-functional team (for example: Design Engineering, QA, Manufacturing Engineering, Purchase, Sales/marketing, etc) that has the skills needed to solve the problem, and that has time and energy to commit to the problem-solving process. Define roles and responsibility of every team member.

Discipline 2: Problem description

            Describe the problem in order to understand what went wrong. It's very important that the complaint be clearly understood as it is the basis of problem solving. Use 5W-2H analysis i.e.

Who?                                                   Identify personnel who is associated with problem

What?                                                  Describe the problem and its severity.

When?                                                 Identify the time when the problem started.

Where?                                                Location of defect.

Why?                                                  Why is this a problem?

How?                                                  In what mode problem occur? 

How many?                                         Quantify the problem

Discipline 3: Implement containment actions

Define and implement containment actions to isolate the effect of the problem from any internal /external customer until corrective action is implemented. Verify the effectiveness of the containment action.

Common containment action examples are:

•           Stoppage of production/dispatch.

•           Segregation i.e. 100% sorting current production and warehouse products.

•           Additional check methods.

•          Tooling change more frequently etc.

Discipline 4: Root cause

            Identify all potential causes i.e. What system allowed for the problem to occur?  And What system allowed for the problem to escape without detection? Do a Cause and Effect Analysis to identify the likely causes of the problem. . Next, apply Root Cause Analysis to find the root causes of the problems you've identified. Isolate and verify the root cause by testing each potential cause against the problem description and test data. Once you identify the source of the problem, develop several permanent solutions to it.

Discipline 5: Choose/verify corrective actions

            Determine which action should be taken to eliminate the problem i.e product/process is controlled. Through pre-production test programs quantitatively confirm that the selected corrective actions will resolve the problem for the customer and will not cause any undesirable side effects.

Discipline 6: Implemented corrective action

            Define and implement the best permanent corrective action. Choose on-going controls to ensure the root cause is eliminated. Monitor this new solution closely for an appropriate period of time to make sure that it's working correctly, and ensure that there are no unexpected side effects.

Discipline 7: Prevent recurrence

            Modify operating systems, practices and procedures to prevent recurrence of this problem and similar problems. Make & use action plan to coordinate required actions. Update relevant documents (process flow diagram, FMEA, Control Plan, MSA, PPAP etc.) 

Discipline 8: Verify, close case & congratulate team

            Check effectiveness of implemented corrective actions, if found satisfactory close the case and congratulate the team.

For 8D methodology format please click on 8D format example