Course overview
The manufacturing industry is now demanding more from its suppliers, mandating a highly structured method to solve problems by identifying and correcting the root causes of events as opposed to simply addressing their symptoms! The “8D Problem Solving” 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 and workshop participants will understand ‘disciplined’ problem solving and be able to facilitate and document value-adding problem-solving exercises using the Eight Disciplines (8D) method to respond to a customer request for corrective action in conformity to industry requirements.
Assessment of learning is achieved through structured exercises and a Case Study. Our tutors provide feedback and advisement to ensure that risk-based thinking, ethical behaviour, human factors and associated best practices are fully understood in the context of the manufacturing industry.
All participants undertake an assessed Case Study to test their application of 8D (we can even use your own real work problems!)
A optional 1½-hour written examination is available at the end of Day-2 based on an individual analysis of an industry specific Study.
The 2-day course is highly interactive and uses Case Studies and group exercises. The course timings are -
Day-1: 08:30 - 17:00
Day-2: 08:30 - 15:30
Day-2: Optional written exam and/or Team Case Study (all open book) - 15:30 -17:00
On-site coaching (option)
TEC also offer on-site coaching session delivered over 1- or 2-days as an option. We facilitate an 8D problem solving session with the organization’s Champion, Team Leader and designated team members.
Course details
The course is delivered over two consecutive days with continual assessment and feedback provided by the tutors. In addition, there is an optionl 1½-hour written examination is available at the end of Day-2.
Preamble – what is a facilitator?
Understanding the roles and responsibilities of a facilitator
Team exercise – trying out ice-breakers
Understanding problems and their causes
Defining problems – the ‘effects’
Agreeing a problem title – ‘thematic’ content
Team exercise – examples of problems
The three types of causes
Understanding ‘logic paths ~ causes
Understanding ‘Boolean logic’ ~ causes
Understanding ‘cause-and-effect’
Understanding the ‘swiss cheese’ model
Understanding ‘human factor’ causes
Team exercise – root cause determination
Systematised problem solving
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
Team exercise – understanding the 8D steps
Facilitator test – explaining 8D to teams
Timelines
Illustrating the 8D process
8D guiding principle – don’t close-off too early
Case Study – illustrating the 8-D process
“The case of the rusty pins”
D0 – Containment and definition of problem
Objective
Actions
Illustration
Essentials
Illustration
Structured questioning – the 4W2H1W
IS – IS NOT questioning
IS–IS NOT questioning – quantified description
Illustration
Team exercise – focus on D0
D1 – Establish the team
Objective
Establish an appropriate team
Actions
Illustration – Champion, Facilitator and Team
Essentials
Team exercise – focus on D1
D2 – Define the problem
Objective
Understand non-conformance to the customer
Illustration
Actions
Problem/Event discovery point
Problem/Event manifestation
Problem/Event impact
Problem/Event focus
Locate the problem/event generation point
Point-of-Cause
Categorical data
Other quantification
Problem/event discovery point
Symptom and problem statement questions
Team exercise – focus on D2
D3 – Implement & verify interim actions
Objective
stem-the-flow & stop-the-bleed
Actions
Containment action
Illustration
Protect ‘the customer’ (stem-the-flow!)
Team exercise – focus on D3
D4 – Identify and verify root causes
Objective
Illustration
Identify possible root cause(s)
Actions
Tools to identify the root cause(s)
Example of tools to identify the root causes
5-WHYs
ISHIKAWA diagram
Using 5-Whys and ISHIKAWA – in tandem!
Find root causes from different ‘perspectives’
Process
System
Understanding ‘root cause’ categories
Process
System
Illustration – Process
Illustration – System
Verifying the root cause – the “therefore test”
Verifying the root cause – “IS – IS NOT test”
Eliminating root causes with "Occam's Razor"
Team exercise – focus on D4
D5 – Select & verify permanent corrective actions
Objective
Actions
Choose and verify corrective action(s)
Classify causes and actions
Preventive
Detection
Illustration
Consider risks and make a choice
Impact-effort matrix
Team exercise – focus on D5
D6 – Implement & validate permanent corrective actions
Objective
corrective actions
process & system
Actions
P-D-C-A cycle
Introduce error proofing wherever possible
Focus on human factors and test inspection
Review and validate the actions
Illustration - confirm actions aimed at the process
Illustration - confirm actions aimed at the system
Team exercise – focus on D6
D7 – Prevent recurrence
Objective
Actions
Prevent recurrence – process and system
Prevent recurrence – template
Illustration
Audit for effectiveness
Team exercise – focus on D7
D8 – Draw conclusions & congratulate team
Objectives
Recognize the success of the (entire) team
Formally close the project
Actions
Review ‘lessons learned’
'read across' & 'corrective action impact'
Draw conclusions and congratulate team
Recognize team and individual contributions
Formally recognize the team effort
Document the effort
Report to top management
Make the recognition ‘high-profile’
Communicate the success – ‘Storyboards’
Team exercise – 8D project close-off
Customer communication
Review the 8D Report for completeness
Illustration
Team exercise – focus on D8
Assessing and auditing 8D – the “8D+” step
Assessing the ‘quality’ of the 8D activity
APPENDIX B – 8D CHECK LIST
Illustration
Team exercise – focus on “D8+”
Practicing 8-D step-1
Team exercise – 5-Whys
The car won’t start!
Tutor evaluation and advisement
Practicing 8-D step-2
Team exercise – ISHIKAWA diagram
The toast burned!
Tutor evaluation and advisement
Evaluating and auditing 8D
Team exercise – Auditing an 8D project
The missing rivets
Tutor evaluation and advisement
Who should attend
Champions/Sponsors, Facilitators and Team Leaders who must respond to customer requests for corrective action using the 8D process and communicate progress using the 8D Problem Solving Form.
Particular emphasis is placed on empowering, as well as qualifying, the individuals who will be facilitating 8D workshops.
Apart from these nominated ‘Facilitators’ all persons participating in the cross-functional problem-solving team will benefit from attending this course.
This is a TEC "Practitioner" course – consequently it incorporates "train-the-trainer"
Deliverables & benefits
Students attending this course will receive a training certificate containing the TEC logo (recognised training provider).
The 8D problem solving methodology covers three key stages of correction and corrective action. This course empowers participants to -
Act rapidly to put immediate containment action in place to protect the customer (stop the bleeding!)
Find and fix the root cause with a permanent corrective action on all current product
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/Sponsor, Facilitator(s) and team members in the 8D problem solving methodology.
Organizations offering 8D problem solving embedded in their QMS will have a distinct competitive advantage
TEC's 2-day course will empower and qualify all of the organization’s cross-functional team members to undertake value-adding 8D problem solving and communicate progress to the customer concerned using the 8-D Problem Solving Form.
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 8D problem solving exercises.