Course Description
When some people hear about “eight disciplines” for solving problems, they immediately think that it must be a complex or convoluted methodology. Actually, the 8D Problem Solving process is really not all that complicated. In fact, a number of common problem-solving models are quite similar to this team-based, data-driven approach to solving problems.
8D is a highly structured and effective scientific approach to solving chronic or recurring problems. It uses team synergy and provides excellent guidelines for identifying the root cause of the problem, implementing containment actions, and then developing and implementing lasting corrective and preventive action.
The 8D Problem Solving methodology is deployed to solve critical, major, chronic and recurring problems. It is most effective in addressing complex problems that exceed the ability of one person to resolve them. In this highly interactive workshop, you will learn how to solve future problems by applying a structured methodology that will yield faster and more effective solutions. The program provides opportunities to practice and apply the technique to case studies and participants’ on-job problems.
In this course, participants will learn how to follow the 8D process steps while working in a cross functional team. They will also apply various problem solving tools to identify and verify a root cause and eliminate it through permanent corrective action, followed by additional action to prevent reoccurrence of the root cause(s). Participants can expect team activities and relevant exercises in a workshop format. All activities will include industry-specific examples and terminology.
Who Should Attend
This course is designed for managers, engineers, scientists, and other professionals involved in their organizations’ process improvement efforts, as well as anyone interested in improving their problem-solving skills and corrective action processes. This workshop is most beneficial when a team from your organization attends together.
Learning Objectives
Upon completion of training, each participant will have the analytical and procedural information needed to understand, describe, and participate in the 8D problem solving process as a team leader, team member, or facilitator.
Course Outline
Welcome and Participant Introductions
List attendees’ personal concerns and objectives for the training
Introduction to Eight Discipline (8D) Problem Solving
What is a problem?
Difficulties and pitfalls in solving problems
What is an 8D?
Getting started on an 8D
Problem awareness/triggers for the 8D
An Overview: 8D Steps and Objectives for Each Step
Knowing what’s to be accomplished at each step
8D Steps 0 and 1
Problem assessment
Preliminary fact gathering
Forming the project team
Roles and responsibilities:
Management
8D champion
Team leader
Team members
Facilitator
8D Step 2: Describe the Problem
The key to effective 8D investigations
Do Step 2 well and 8D flows smoothly
“A problem well-defined is a problem half-solved.” (B. Fuller)
Kepner-Tregoe/IS/IS NOT/Systematic Root Cause Analysis
Six steps to Systematic Root Cause Analysis
Naming the problem
Describing the problem (problem specification)
Problem specification dimensions and questions
IS/IS NOT problem description
Deriving distinctions and changes from the IS/IS NOT Information Break
8D Step 3: Containment
Types of containment activities
Monitoring and verifying containment effectiveness
Containment does not solve the problem!
Step 4: Identify Root Cause(s)
“Occurrence, escape and systemic” root causes
Tools employed at Step 4
Process flow/process maps
Brainstorming
Cause-and-effect (CE) analysis
CNX (control, noise, experiment)
Standard Operating Procedure (SOP)
Test theories of causes against problem description (Step 2 above)
Workshop to Apply Step 4 Tools
Step 5: Develop and Verify Solution
Considerations and objective
Developing and selecting solutions
Verifying that the solution is effective
Error-proofing
Step 5 Checklist
Step 6: Implement and Validate Corrective Action
Objective and highlights of Step 6
Developing an action plan for implementation
Issues to be addressed in plans for implementation and verification
Be sure to update FMEA, control plan and other documents to reflect
Changes and improvements introduced at Step 6
Examples of 8D Steps 5 and 6
Step 7: Prevent Problem Reoccurrence
Considerations: Extend the fix; extend the cause, stair-step the cause
Look at the problem and solution systemically
“Drill deep” to address systemic root cause(s)
Change/update management systems
Emphasis shifts to prevention
Step 8: Recognize the Team
Recognize and publicize the team’s accomplishments
Don’t keep your candle under a bushel!
Make sure customers (internal and external) know about the successful application of the 8D methodology.
Prerequisites
none
Course Format
16 hours
Combination lecture and classroom exercises
Available at QSG’s training facilities, on-site at your organization, and virtually
Course instructors:
Angelo Scangas – CEO and Chief Customer Officer
Bob Deysher – Senior Consultant, Quality Systems/Risk Management/Auditing
Laura Halleck – Senior Consultant, Quality Systems Auditing (Automotive, Aerospace)
Ed McFayden – Consultant, Quality Systems, Lean Six Sigma, Auditing
Kush Shah – Senior Consultant, Lean Six Sigma
Jim Wasson – Consultant, Lean Six Sigma/Process Improvement
8:30am-4:30pm (EST) each day
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