Aerospace/Defence Problem Solving - based on AS13000

In an effort to ensure that problems only ever occur once; and are then fixed permanently; the global aero-engine manufacturers have collaborated to create AS13000 which is a standard customised for the industry using a step-by-step problem solving methodology popularized by Ford Motor Company and Toyota in the 80’s.

Known as ‘8-D problem solving’ it is a highly structured method that solves problems by identifying and correcting the root causes of events as opposed to simply addressing their symptoms! The methodology is structured into eight disciplines, emphasizing a cross-functional team synergy and the use of designated quality tools and techniques.

By the end of this 2-day interactive course participants will understand ‘disciplined’ problem solving and be able to facilitate and document value-adding problem solving exercises using the Eight Disciplines (8-D) method to respond to a customer request for corrective action in conformity to AS13000 requirements.

Assessment of learning is achieved through structured exercises and an aerospace Case Study.The tutors provide feedback and advisement to ensure that risk-based thinking, ethical behaviour and associated best practices are fully understood in the context of the aerospace/defence industry.

  • All participants undertake an assessed Case Study to test their application of 8-D
  • A 1½-hour written examination is available as an option at the end of Day #2 based on their analysis of an Aerospace Case Study.

The 2-day course is highly interactive and uses Aerospace Case Studies and group exercises. The course timings are -

  • Day #1: 08:30 - 17:00
  • Day #2: 08:30 - 15:30
  • Day #2: Written exam (optional) or Team Case Study - 15:30 -17:00

On-site coaching (option)

TEC Transnational also offer on-site coaching session delivered over 1- or 2-days as an option. We facilitate an 8-D problem solving session with the organization’s Champion, Team Leader and designated team members.

The course is delivered over 2 consecutive days with continual assessment and feedback provided by the tutors.In addition, there is an optional 1½-hour written examination is available at the end of Day #2.

Course topics include –

The 8-D process steps

  • D0 – Implement immediate containment and prepare for 8-D
  • D1 – Form the team
  • D2 – Define the problem
  • D3 – Develop containment actions
  • D4 – Identify and verify root cause(s)
  • D5 – Identify corrective action
  • D6 – Implement corrective action
  • D7 – Define and plan preventive action
  • D8 – Recognize the team

A key step is D4 “Identify and verify root cause(s)” which demands that the cross-functional team apply a battery of specified quality tools and techniques for identifying and verifying root causes which are incorporated in the course –

Tools for data collection

  • Data collection forms
    • Measuring (continuous)
    • Counting
    • Appraisal (attribute)
    • Contextual (categorical)

Tools for data analysis

  • Check-sheets (Tally charts)
  • Measles charts
  • Run Charts
  • Histograms
  • Scatter Diagrams
  • Control Charts
  • Process Mapping
  • Design of Experiments (DoE)
  • Pareto, etc.

Tools for determining root causes

  • Human factors
    • identifying the 'dirty dozen' of causes
  • Brainstorming
    • round-robin variant
    • brain-writing variant
  • Linear 5-WHYs
  • 5-WHY trees
    • eliminating 'unlikely' causes
    • alternative 'paths' (root cause chains)

Case studies (identifying root causes)

Case study #1

  • fishbone diagram
  • affinity diagram

Case study #2

  • determining the scope and scale of the problem
  • using FTA (Fault Tree Analysis)
  • locating the 'escape point'
  • structured questioning - 4W2H1W
  • Is - IS NOT questioning methodology

Identifying the true root cause

  • 5-WHYs logic path
  • applying the 'therefore test'

Understanding the three perspectives

  • direct root cause
  • detection root cause
  • systemic root cause

Illustrated case study

Case study: "The Missing Rivets"

Public course

Our public courses are run at the Woodland Grange Conference Centre in Warwickshire

The course fee includes a 3-course lunch and refreshments during both days

Course dates
On-site course

In-company courses may be organised at any time and are extremely cost-effective on a ‘cost-per-student’ basis. The host company is responsible for the venue costs.

We can accommodate up to 10 (maximum) delegates per session.

Details/quote

Champions and Team Leaders who must respond to customer requests for corrective action using the 8-D process and communicate progress using the 8-D Problem Solving Form of AS13000.

Apart from nominated ‘Team Leaders’ all persons participating in the cross-functional problem-solving team will benefit from attending this course.

The 8-D problem solving methodology covers three key stages of correction and corrective action.This course empowers participants to -

  1. Act rapidly to put immediate containment action in place to protect the customer (stop the bleeding!)
  2. Find and fix the root cause with a permanent corrective action on all current product
  3. Prevent the recurrence of the problem in the future by identifying and implementing preventive action anywhere possible within the organization

Organizations need to empower a Champion, Team Leader(s) and team members in the 8-D problem solving methodology in line with the requirements of AS13000 and the soon-to-be-published IAQG 9136 standard.

Organizations offering 8-D problem solving embedded in their QMS will have a distinct competitive advantage.

TEC's 2-day course will empower all of the organization’s cross-functional team members to undertake value-adding 8-D problem solving and communicate progress to the customer concerned using the 8-D Problem Solving Form of AS13000.

The individuals attending will learn how to use a set of powerful quality tools for both data collection and analysis.In addition they will be able to plan and facilitate 8-D problem solving exercises.

A 1½-hour written examination is available as an option at the end of Day #2 based on the analysis of an Aerospace Case Study.

Alternatively, the organization chooses to provide a real problem for solution. This then replaces the illustrated case study and the written examination.

Larger teams might benefit from our in-house courses. Fill out the form below and we will contact you with further details.

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