8D Problem Solving Guide & Methods
8D Problem Solving Guide & Methods
ARA TRAINING
Success
Data Knowledge
Driven Driven
Integrate
Question
Driven
- © 2015 - 5 ARA (Dec 15)
Basic Problem Solving
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Utilize Simple Tools
Why is it a Problem?
Be
Adaptive
Plan
(Define Problem, Pick Factors, …)
Act
(Make Conclusion, Define Next Step) Do
(Design / Execute Experiments)
Check
(Analysis / Implementation / Verification)
- © 2015 - 10 ARA (Dec 15)
Basic Problem Solving
Organize a Team
Clarify Problem
Understand Problem
Select Solution
Kepner - Tregoe
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How is It Similar?
How Different?
How Complete?
[Link]
Consensus-Oriented Decision-Making
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The CODM model was developed by psychologist, Dr. Tim Hartnett, and it was published his 2010 book
Consensus-Oriented Decision-Making
(8)
Document (1)
Results & Form Team
Recognize
Team (2)
(7) Define
Prevent Problem
Recurrence 8D
(6) Process (3)
Verify Implement
Corrective Containment
Actions (5) (4)
Identify Root Identify
Cause Corrective Possible Root
Actions Causes
D1 D2 D3 D4 D5 D6 D7 D8
Previous
3/13/13 3/13/13 3/16/13 3/23/13 3/24/12 3/25/13 3/26/13 3/27/13
Review
Current
3/13/13 3/13/13 3/17/13 3/23/13 3/25/13 3/25/13 3/26/13 3/27/13
Plan
Note: Add Any Key Customer Delivery Dates / Description Above if Different From Dx
- © 2015 - 18 ARA (Dec 15)
4D Project Overview Basic
Template
Problem Solving
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Problem Definition Business Impact Key Requirements
Performance Customer Revenue $10M Eliminate Customer Line Fallout
Gap: Line Fallout
No Change in Any Product Spec
Actual = 1,000 PPM Customer
Medium
Target = < 10 PPM Relationship < 3% Increase in Product Cost
Time in Organization High < 10% Increase in Step Mfg Cycle Time
90 Days
Existence
Containment Impact
Time to Solve < 7 Days Problem Complexity Customer: None
Product/Service Touch Sensor
Type (L,M,H) Medium Manufacturer: 5% Yield Loss ($0.50)
Customer Apple
COL Budget Mfg: 20% Capacity Reduction (1Mu/Mth)
Organizations PE, TE, Mkt 4
(Fcst/Actual) Mfg: 10% Increased Cycle Time (6 Hrs)
Priority (1 – 5) 4
Time Per
24 Hrs Root Cause / Corrective Action
Team Lead Isabel Cycle
RC Hypothesis/Confirmed: Test Hole at X
Team KY, TA, KG, ..
CA Status: In Progress
Current
3/13/13 3/13/13 3/17/13 3/23/13
Plan
Note: Add Any Key Customer Delivery Dates / Description Above if Different From Above
- © 2015 - 19 ARA (Dec 15)
Basic Problem Solving
(Don’t Over-Complicate)
Describe Problem Clear, Concise Problem Definition
(With Data) Starts With Broad Perspective
Gets Alignment Across Organizations
Breaks Down Problem
Propose Questions Data, Knowledge Base, Assumptions
Hypotheses Critically Focuses Data
Eliminates Artificial Constraints
Test Hypotheses Drives Convergence & Critical Path
(With Data) Is Self-Correcting
Balances Planning & Doing
Balances Root Cause Fix & Containment
Implement Is Properly Tracked & Progress Communicated
Appropriate Fix
Appropriately Documented
- © 2015 - 20 ARA (Dec 15)
Basic Problem Solving
Cooperation
Communication
- © 2015 - 21 ARA (Dec 15)
Basic Problem Solving
ARA TRAINING
Plan
(Define Problem, Pick Factors, …)
Act
(Make Conclusion, Define Next Step) Do
(Design / Execute Experiments)
Check
(Analysis / Implementation / Verification)
- © 2015 - 23 ARA (Dec 15)
Basic Problem Solving
(1)
Form Team
(8)
Document
Results &
Recognize
Team (2)
(7) Define
Prevent Problem
Recurrence 8D
(6) Process (3)
Verify Implement
Corrective Containment
Actions (5) (4)
Identify Root Identify
Cause Corrective Possible Root
Actions Causes
I. Form Team
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(8) (2)
Define
Document (1)
Results & Form Team
Problem
Recognize
Team
(7)
Prevent
Recurrence 8D
(6) Process (3)
Verify Implement
Corrective Containment
Actions (5) (4)
Identify Root Identify
Cause Corrective Possible Root
Actions Causes
Crises:
Fast Action, Big Differences
Simple Experiments U
R
Development/Yield Enhancement G
More Time, Smaller Differences, Cause & Effect E
2 Level Factorials, Blocked Designs N
C
Discovery Y
Longer Time, Complete Knowledge
Response Surface, Steepest Ascent
D. Welter, Motorola
- © 2015 - 28 ARA (Dec 15)
Basic Problem Solving
Extent ?
How ?
Does it Interact ?
“Solved” Before ?
What Can Be Done to Clarify Problem?
Preliminary Hypothesis Driven?
Who Can Help?
...
- © 2015 - 32 ARA (Dec 15)
Basic Problem Solving
5 Ws . . . and . . . 2 Hs
(Who, What, Why, Where, When) (How Many, How Often)
IS IS NOT
Who Who
Who is affected by the problem? Who is not affected by the problem?
Who first observed the problem? Who did not find the problem?
To whom was the problem reported?
What What
What type of problem is it? What does not have the problem?
What has the problem (part id, lot #s, etc)? What could be happening but is not?
What is happening with the process? What could be the problem but is not?
What changed?
Do we have physical evidence of problem?
Why Why
Why is this a problem? Why is it not a problem?
Is the process stable (Or Unstable)? After ABB 8D Worksheet
- © 2015 - 33 ARA (Dec 15)
Basic Problem Solving
IS IS NOT
Where Where
Where was the problem observed? Where is the problem not observed?
Where does the problem occur? Where is the problem not located?
When When
When was the problem first noticed? When could the problem have been
When has it been noticed since? noticed but was not?
Analysis Tools:
Simple (Or Even Multivariate) Correlation Analysis
Multi-Vari Charts
Distribution Analysis and Box Plots
...
Something Change . . . Or . . .
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Performance
Target Target
Level
Level
Actual Actual
Time Time
Desired
Level
Actual
Time
- © 2015 - 36 ARA (Dec 15)
Basic Problem Solving
Multi-Vari Chart
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Stepper
1 2 3 4
Data Knowledge
Driven Driven
Integrate
Question
Driven
- © 2015 - 38 ARA (Dec 15)
Basic Problem Solving
Applicability
...
Don’t Take “Knowledge” at Face Value
- © 2015 - 40 ARA (Dec 15)
Basic Problem Solving
Matthies’ PQ Basic 7 8
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Argument Deconstruction
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Conclusion
Reason/Evidence
Assumption 1 . . .
Assumption 2 . . .
. . . Assumption n
Source
Stay Alert to Implicit Assumptions
& Weak Source(s) After Dennis Matthies
- © 2015 - 43 ARA (Dec 15)
Basic Problem Solving
Verify /
High Accept
Double-Check
Underlying
Assumption
Support
Validity
Low Reframe
Investigate &
Reframe
Low High
Consequence of Assumption
Assumptions: Constraints
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(8)
Document (1)
Results & Form Team
Recognize
Team (2)
(7) Define
Prevent Problem
Recurrence 8D
(6) Process (3)
Verify Implement
Corrective Containment
Actions (5) (4)
Identify Root Identify
Cause Corrective Possible Root
Actions Causes