rolls royce 8d problem solving

• Training Venues

AS9145 APQP and PPAP Essentials

AS9145 APQP and PPAP Practitioner

AS13100 aligned RM13145 PPAP Co-ordinator and CARe training course

eAPQP & PPAP NetInspect Essentials Training

AS9145 APQP and PPAP Essentials & AS9145 APQP and PPAP Practitioner:

Senior Managers, Management Representatives, Implementation Teams, Internal Auditors and others who are involved in the auditing or implementation of Advanced Quality Planning (AQP) activities including Control Plans.

AS13100 aligned RM13145 PPAP Co-ordinator and CARe training course:

This course is designed to meet the qualification requirements of AESQ RM13145. Attending this training course and passing the end of course exam qualifies delegates in the role of PPAP Coordinator or CARe as required by the AESQ. Attendance would also benefit those persons tasked with auditing of the organisations APQP/PPAP process.

Team to Team Working (eAPQP & PPAP) using NetInspect Software Tool:

This course is designed for all organisations who are working with a customer that requires eAPQP population in order to track project deliverables. The course is suitable for: Program Managers, Manufacturing Engineers, Quality Engineers, and Design Engineers.

AS13100_RM13004 Defect Prevention Quality Tools to Support APQP & PPAP (Including FMEA and Control Plan)

SAE AS13100™ Standard 2nd Level Documents

AS13100_RM13003 – Measurement System Analysis (MSA)

AS13100_RM13006 – Process Control Methods

AS13100_RM13000 8D Problem Solving

SAE AS13100™ System Documents

AS13100_RM13005 Quality Audit – (Aerospace Internal Auditor)

AS13100_RM13005 Quality Audit – (Aerospace Internal Auditor): This course is designed for auditors supporting an organisations internal audit programme and others who have a working knowledge of quality systems within the aerospace sector and/or any previous auditing experience.

This course will help auditors develop relevant skills in judgment, decision making, audit planning, audit non-conformity writing and subsequent close out related to the aerospace IAQG 9100/9110/9120 QMS standards, AS13100 and AESQ RM13005. Internal auditing and familiarity with ISO 9001 and IAQG 9100/9110/9120 would be beneficial but not a necessity.

• Customer Support
• +1 845-393-2870
• AlisQI QMS for manufacturing
• Quality Control with integrated SPC
• Document Management System
• EHS Management
• No-code QMS platform
• QMS Integrations
• Plastics and packaging
• Food & beverage
• Technical textiles
• Other industries
• QA / QESH Manager
• Plant Manager
• Statistical Process Control
• LIMS for manufacturing
• Shop floor operations
• Customer case studies
• Whitepapers
• Webinars & Events
• Free courses
• ROI calculator
• QMS vendor selection
• Help Center
• LIMS vs QMS
• Culture of Quality
• Cost of Quality
• News & Awards
• AlisQI Academy
• AlisQI Developer portal

Need to convince stakeholders that you need a QMS? Want to test your quality management maturity?

• Webinars & Events NEW
• Take a product tour

Don't take our word for it. Read what our customers say on Gartner Peer Insights .

• About AlisQI
• AlisQI Help Center

8D problem solving: how to diagnose & eliminate quality problems

Diagnosing and eliminating quality problems is at the heart of all Quality Management. There are several methodologies as to how to do this. One of the most widely implemented is 8D problem solving. This tried-and-true methodology gives teams a comprehensive and consistent way to address production problems, no matter where they are triggered along the production chain.

Several articles elaborate on why it’s important to diagnose and eliminate quality problems using the 8Ds. But how does this work if you’re using  quality management software ? Let’s find out

A quick intro to 8D problem solving

The Eight Disciplines of problem solving (8D) provides manufacturers with a team-oriented approach to addressing problems in the production cycle. It’s widely used throughout manufacturing and combines best practices from a variety of approaches to create a “best of all worlds” scenario. High-level goals folded into the 8D process include:

• Identifying the root cause of a problem
• Developing containment actions that protect customers

Organizations that employ 8D should experience systemic changes to their production process. They will also be able to improve and streamline the whole process. This helps them to eliminate the problem at hand but also reduce the occurrences of other problems down the line

So, what do the 8Ds stand for?

To achieve the high-level goals described above, a team should pursue these eight steps:

• Define the stakeholders addressing the problem.
• Develop a Problem Statement that correctly summarizes and defines the problem.
• Define and execute an interim containment action.
• Document the root cause of the non-conformance or non-detection, along with the                percentage at which it contributed to the problem.
• Define, select, and verify Corrective Action(s) needed to address the problem.
• Implement and validate the Corrective Action(s).
• Document all actions taken to prevent recurrence.
• Document and acknowledge the team contributions that led to the success of this                  process.

When to apply 8D problem solving

Typically, 8D is most applicable in the following scenarios:

• when safety or regulatory issues have come up in the production cycle
• if your company receives multiple and consistent customer complaints
• when warranty responses suggest product failure rates that are higher than expected
• in case internal factors such as waste, test failures, rejects or poor performance occur at  unacceptably high levels

Why apply 8D problem solving

Next to a collaborative and consistent way to address production problems, 8D also delivers other benefits including but not limited to:

• developing team-wide skills when it comes to solving production problems
• creating an ongoing record of failures that can inform problem solving efforts to come
• improved understanding of statistical tools leveraged in problem solving
• improved efficiency and effectiveness in team efforts to solve problems
• a better understanding of RCA (Root Cause Analysis)
• developing problem solving skills that can be adapted for other areas/departments in a          company
• enhanced skills when it comes to taking corrective actions
• enhanced collaboration and discussions around problem solving
• enhanced ability by the team to identify where change is needed
• improved management understanding of processes

How to leverage 8D if using quality management software

One of the most effective ways to leverage the 8D method is by applying it using a smart QMS. The cloud-based quality management system from AlisQI was designed to help manufacturers work smarter, not harder. We automate data collection, data analysis, project management and other routine tasks so that manufacturers can focus on continuous improvement.

Within AlisQI manufacturers have a QESH problem-solving page, a standardized dashboard based on the 8D methodology. Whether it’s a complaint, deviation or safety incident, this page provides all the components you need to analyze, follow up on and report production problems. It is available for all QESH processes, no matter their context.

A closer look at the Problem-solving page

The QESH problem-solving page is divided into four sections. Together, they make for an integrated approach to problem solving. To be more specific:

• Incident details This presents all information entered via the form to register or follow up on an incident. The form can be fully tailored. It details tasks leading up to the incident, the damage that occurred as well as immediate actions that have been taken.
• Attachments Uploaded images depicting the incident are shown right away. Other file types are linked and easily accessible. Teams can add just about any file type as an attachment. Typical examples include images, Word, Excel, PPT, or PDF files.
• CAPA actions Shows all connected corrective or preventive actions related to the incident, with their owner, due date, and status. The moment you assign an action, the action owner is informed automatically. The CAPA actions are managed centrally, so you always know who is doing what.
• Root cause analysis The lower right quadrant shows an example of five times why root cause analysis. This allows for a systematic approach to root cause findings.

Additionally, the smart QMS allows for the creation of full-featured 8D reports (including all actions and their status).

Do you want to learn more and actively use 8D problem solving to improve production? Book a free online demo, and we’ll show you how to set up effective QESH management so that you can focus on improving your business.

Otto de Graaf

Related articles.

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

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) :

• Assess whether the problem really exists
• Is there a deviation from what it should be?
• Is the customer’s complaint valid?
• Is the claim covered by the product’s warranty, or was it misused?
• Assess who are the people in the company who can contribute to solving the problem (which areas should participate in the discussions?)
• Team Formation
• Problem Description
• Characterize the problem
• Get the first data about the problem (where/when/what?)
• Translate the customer’s language into the company’s language
• Understanding customer dissatisfaction, to bring it to the team
• Immediate Actions / Containment
• Discuss over time what can be done to minimize the effect of the problem
• Take action so that the customer does not continue to receive products with the same problem
• Looking for actions to contain the symptom of the problem (without knowing the cause)
• Find Root Cause of the Problem
• 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)
• 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)
• 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)

• Proof of the Effectiveness of Corrective Actions
• Evaluate each of the actions defined in Step 4, regarding their effectiveness in solving the problem
• 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)
• Perform small-scale tests and evaluate possible side effects.

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

• Preventive Actions Against Recidivism Discuss with the team what should be done to:
• Do not allow the failure not to happen in the future (re-incidence)
• Extend as elaborated in Step 6 to similar processes and/or locations that may present the same problem (prevention)
• Transform actions into “best practices”
• FMEA Review
• Lessons Learned / Yokoten
• Presentation of Results and Celebrating the successful resolution of the problem with the team
• Present the actions taken and the results obtained, to the team, to ensure the learning of its members
• Recognize the effort and dedication of the team (involve managers)

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 .

Share this:

Interesting article.

8D Problem Solving: The Key to Effective Root Cause Analysis

Author: Daniel Croft

Daniel Croft is an experienced continuous improvement manager with a Lean Six Sigma Black Belt and a Bachelor's degree in Business Management. With more than ten years of experience applying his skills across various industries, Daniel specializes in optimizing processes and improving efficiency. His approach combines practical experience with a deep understanding of business fundamentals to drive meaningful change.

Are you tired of putting out fires and dealing with the same issues over and over? It’s time to sharpen your problem-solving abilities with the effective 8D methodology. The 8D process is a methodical approach to solving complex problems and developing long-term solutions. In this blog post, we will explore the key principles of 8D problem solving and demonstrate how to effectively implement this process in your organization for continuous improvement and success.

Support your 8D Problem solving with our 8D Problem Solving Template

What is 8D Problem Solving?

8D Problem Solving is a structured and systematic problem-solving approach that is intended to find and implement long-term solutions to complex problems. It is a team-based methodology with eight defined steps that are intended to guide the problem-solving process in a structured and effective manner. The goal of 8D Problem Solving is to identify the root cause of a problem and implement corrective actions to keep it from happening again. The 8D process is flexible and adaptable, allowing it to be applied to a wide range of problems and industries.

One of the most significant benefits of 8D Problem Solving is its team-based approach. This approach promotes collaboration and teamwork, as well as the exchange of ideas and expertise among people from various departments or backgrounds. This helps to ensure that all relevant perspectives are considered and that the best solution is found. Furthermore, 8D Problem Solving fosters a mindset of continuous improvement by encouraging organisations to identify and solve problems before they escalate and to continuously monitor progress over time.

Therefore, 8D Problem Solving is a powerful tool that can assist organisations in identifying and implementing effective solutions to complex problems. Because of its structured and systematic approach, as well as its emphasis on root cause analysis and continuous improvement, it is an effective method for organisations of all sizes and industries.

The Benefits of 8D Problem Solving:

• Aids in determining the root cause of problems rather than just treating symptoms
• Promotes continuous improvement by preventing recurring problems
• Helps organisations identify and correct problems before they escalate by providing a structured and systematic approach to problem-solving.
• Organizations can use the 8D process to effectively resolve problems and continuously improve their processes for greater efficiency and success.

The 8 Steps of 8D Problem Solving

The 8D process is a cyclical method for problem-solving that is organised and systematic. It consists of eight steps that guide the problem-solving process and aid in the achievement of a successful outcome. The procedure is as follows:

D1 : Form a Team – This step entails assembling a group of people with relevant expertise and experience to work on the problem.

D2 : Describe the Problem – This step entails clearly defining the problem by describing symptoms, and potential consequences, and gathering data to back up the description.

D3 : Interim Containment Actions – In this step, temporary measures are implemented to contain the problem until a permanent solution is found.

D4 : Root Cause Analysis – this step entails determining the root cause of the problem in order to effectively address it.

D5 : Corrective Actions – this step entails creating and implementing a plan of action to address the underlying cause of the problem.

D6 : Corrective Action Implementation – This step entails carrying out the corrective actions.

D7 : Corrective Action Verification – This step involves validating the effectiveness of the corrective actions.

D8 : Long-Term Corrective Actions – this step entails putting in place and monitoring long-term solutions to keep the problem from recurring.

Each step in the 8D process is interconnected, and it is critical to complete each step thoroughly to ensure a successful outcome. Organizations can solve complex problems in a structured and effective manner by following the 8D process.

Best Practices for 8D Problem Solving

Clearly Define the Problem: The first step in solving a problem is clearly defining it. This entails describing the symptoms and potential consequences of the problem, as well as gathering data and information to back up the description.

Involve All Stakeholders: It is critical to include all stakeholders in the problem-solving process to ensure a successful outcome. Individuals or departments with relevant expertise and experience, as well as those affected by the problem, are included.

Focus on Root Causes, not Symptoms: It is critical to focus on finding the root cause of a problem rather than just treating its symptoms in order to effectively solve it. Methods of root cause analysis, such as 5 Whys or Fishbone diagrams, can aid in this process.

Verify Corrective Actions: Once corrective actions have been implemented, it’s important to validate their effectiveness. This includes ensuring that the problem has been fully addressed and that the corrective actions are long-term.

Follow-Up and Monitor Progress: Because the 8D process is a tool for continuous improvement, it’s critical to follow up on the problem-solving process and track progress over time. This includes regular check-ins to ensure that corrective actions are being implemented as intended and to identify any new or recurring problems. Organizations can ensure a successful 8D problem-solving process and continuously improve their processes for greater efficiency and success by adhering to these best practices.

Example of 8D being used to address a customer complaint.

The following is an example of an 8D process used in the manufacturing sector to address a customer complaint:

D1: Create a Team – A cross-functional team of representatives from production, quality control, customer service, and engineering is formed. The team leader is chosen, and the roles and responsibilities of the team members are established.

D2: Describe the Problem – The customer complaint is reviewed and the problem is described as a “defective product delivered to the customer”. The information gathered from the customer and from internal investigations is used to precisely define the problem .

D3: Interim Containment Actions – Interim containment actions are taken to reduce the impact of the problem. To prevent the affected product from being delivered to other customers, the team implements a hold and quarantine procedure.

D4: Root Cause Analysis – The team employs the 5 Whys method to identify the underlying cause of the problem. The root cause is discovered to be a machine malfunction that went unnoticed during the manufacturing process.

D5: Corrective Actions – The team devises a strategy to address the underlying cause of the problem. The plan includes repairing the malfunctioning machine as well as performing regular machine maintenance checks to avoid similar problems in the future.

D6: Carry Out Corrective Actions – The plan of action is carried out, the machine is repaired, and preventive maintenance checks are carried out.

D7: Verify Corrective Actions – The team conducts an internal audit and checks that the machine is functioning properly to ensure that the corrective actions have effectively addressed the root cause of the problem.

D8: Prevent Recurrence – To avoid a recurrence of the problem, the team updates the procedures and processes for machine maintenance checks, as well as providing additional training to production staff. The team also reviews and updates the process on a regular basis to ensure continuous improvement.

The manufacturing company was able to effectively resolve the customer complaint, minimise its impact, and prevent recurrence by following the 8D process.

In Conclusion, 8D Problem Solving is a structured and effective method for dealing with complex issues in any industry. This process brings together a cross-functional team to analyse and solve problems systematically, resulting in long-term solutions and continuous improvement. Organizations can ensure they address the root cause of problems and prevent recurrence by following the eight defined steps. 8D Problem Solving is a useful tool for businesses that want to improve their processes and customer satisfaction. 8D Problem Solving, when approached and implemented correctly, can lead to increased efficiency, increased customer satisfaction, and improved bottom-line results.

Was this helpful?

Daniel Croft

Daniel Croft is a seasoned continuous improvement manager with a Black Belt in Lean Six Sigma. With over 10 years of real-world application experience across diverse sectors, Daniel has a passion for optimizing processes and fostering a culture of efficiency. He's not just a practitioner but also an avid learner, constantly seeking to expand his knowledge. Outside of his professional life, Daniel has a keen Investing, statistics and knowledge-sharing, which led him to create the website www.learnleansigma.com, a platform dedicated to Lean Six Sigma and process improvement insights.

The Benefits of Becoming a Lean Six Sigma Yellow Belt Professional

Beware of TIM WOODS: The Eight-Headed Monster in Your Business

Free lean six sigma templates.

Improve your Lean Six Sigma projects with our free templates. They're designed to make implementation and management easier, helping you achieve better results.

5S Floor Marking Best Practices

In lean manufacturing, the 5S System is a foundational tool, involving the steps: Sort, Set…

How to Measure the ROI of Continuous Improvement Initiatives

When it comes to business, knowing the value you’re getting for your money is crucial,…

8D Problem-Solving: Common Mistakes to Avoid

In today’s competitive business landscape, effective problem-solving is the cornerstone of organizational success. The 8D…

The Evolution of 8D Problem-Solving: From Basics to Excellence

In a world where efficiency and effectiveness are more than just buzzwords, the need for…

8D: Tools and Techniques

Are you grappling with recurring problems in your organization and searching for a structured way…

How to Select the Right Lean Six Sigma Projects: A Comprehensive Guide

Going on a Lean Six Sigma journey is an invigorating experience filled with opportunities for…