8D Problem Solving Worksheet

8D::ProblemSolvingWorksheet TrackingNumber: CustomerNumber: ResponseDueDate: 8-Disaqualitymanagementtoolandisavehicleforacross-functionalteamtoarticulatethoughtsandprovidesscientificdeterminationtodetailsofproblemsandprovidesolutions.Organizationscanbenefitfromthe8-Dapproachbyapplyingittoallareasinthecompany.The8-Dprovidesexcellentguidelinesallowingustogettotherootofaproblemandwaystocheckthatthesolutionactuallyworks.Ratherthanhealingthesymptom,theillnessiscured,thus,thesameproblemisunlikelytorecur. Step 0 1 2 3 4 5 6 7 8 Action ThePlanningStage EstablishingtheTeam ProblemDefinition/Statement&Description DevelopingInterimContainmentAction Identifying&VerifyingRootCause IdentifyingPermanentCorrectiveActions(PCA) Implementing&ValidatingPCA PreventingRecurrence RecognizingTeamEfforts 0 ThePlanningStage:The8-Dmethodofproblemsolvingisappropriatein"causeunknown"situationsandisnottherighttoolifconcernscentersolelyondecision-makingorproblemprevention.8-Disespeciallyusefulasitresultsinnotjustaproblem-solvingprocess,butalsoastandardandareportingformat.Doesthisproblemwarrant/requirean8D?Ifsocommentwhyandproceed. IsanEmergencyResponseActionNeeded?(IfneededdocumentactionsinActionItemTable) 1 EstablishingtheTeam:Establishasmallgroupofpeoplewiththeprocess/productknowledge,allocatedtime,authorityandskillintherequiredtechnicaldisciplinestosolvetheproblemandimplementcorrectiveactions. TeamGoals:TeamObjectives: DepartmentNameSkillsResponsibility 2A ProblemDefinitionProvidesthestartingpointforsolvingtheproblemornonconformanceissue.Needtohave“correct”problemdescriptiontoidentifycauses.Needtousetermsthatareunderstoodbyall. Sketch/PhotoofProblem PartNumber(s): Customer(s): Listallofthedataanddocumentsthatmighthelpyoutodefinetheproblemmoreexactly? ActionPlantocollectadditionalinformation: PrepareProcessFlowDiagramforproblemuseaseparatesheetifneeded 2B IS ISNOT Who Whoisaffectedbytheproblem?Whofirstobservedtheproblem?Towhomwastheproblemreported? Whoisnotaffectedbytheproblem?Whodidnotfindtheproblem? What Whattypeofproblemisit?Whathastheproblem(partid,lot#s,etc)?Whatishappeningwiththeprocess&withcontainment?Dowehavephysicalevidenceoftheproblem? Whatdoesnothavetheproblem?Whatcouldbehappeningbutisnot?Whatcouldbetheproblembutisnot? Why Whyisthisaproblem(degradedperformance)?Istheprocessstable? Whyisitnotaproblem? Where Wherewastheproblemobserved?Wheredoestheproblemoccur? Wherecouldtheproblembelocatedbutisnot?Whereelsecouldtheproblembelocatedbutisnot? When Whenwastheproblemfirstnoticed?Whenhasitbeennoticedsince? Whencouldtheproblemhavebeennoticedbutwasnot? HowMuch/Many Quantityofproblem(ppm)?Howmuchistheproblemcostingindollars,people,&time? Howmanycouldhavetheproblembutdon’t?Howbigcouldtheproblembebutisnot? HowOften Whatisthetrend(continuous,random,cyclical)?Hastheproblemoccurredpreviously? Whatcouldthetrendbebutisnot? 2C ProblemDescription(basedontheinformationgatheredsofar,provideaconciseproblemdescription) 3 DevelopingInterimContainmentActionsTemporaryactionstocontaintheproblemand“fix”untilpermanentcorrectionisinplace-documentactionsinActionItemTable 4A Identifying&VerifyingRootCauseAnalyzefor“RootCause”oftheproblem.IdentifyandverifytheEscapePoint Brainstormthepossiblecausesoftheproblem 4A CauseandEffectDiagram circlethemostlikelycontributors(amaximumofthree)fromeachside. 4B 5WhyAnalysis Ask–Whydidthishappen?Ask–Whydidthishappen?Ask–Whydidthishappen?Ask–Whydidthishappen?Ask–Whydidthishappen? 4C ActionPlanBasedontheteam’sdiscussions.BegintocompletetheRootCauseActionPlantoverifyandvalidatetherootcausesandtesttheescapepoint.DocumentthisontheActionItemTable 5 IdentifyPermanentCorrectiveActionssolutionsthataddressandcorrecttherootcause.Solutionsdeterminedtobethebestofallthealternatives.DocumentandverifythePermanentCorrectiveAction(PCA)intheActionItemTable 6 Implementing&ValidatingthePCAImplementandvalidatetoensurethatcorrectiveactiondoes“whatitissupposedtodo.”Detectanyundesirablesideeffects.DocumentthisontheActionItemTable.Returntorootcauseanalysis,ifnecessary 7 PreventingRecurrencedeterminewhatimprovementsinsystemsandprocesseswouldpreventproblemfromrecurring.Ensurethatcorrectiveactionremainsinplaceandsuccessful 7A AddressSimilarSystems Process/ItemWhoResponsibleWhen 7B Reviewthefollowingdocuments/systems Document WhoResponsible CompletionDate Planned Actual ManagementSystemManual ManufacturingWorkInstructions InspectionWorkInstructions ProcessFlowCharts ProcessControlPlans DesignFMEA ProcessFMEA Gages PPAP EngineeringChangeApproval 8 CongratulateYourTeamUseallformsofemployeerecognitionanddocumentasnecessaryCelebratesuccessfulconclusionoftheproblemsolvingeffortFormallydisengagetheteamandreturntonormalduties Wasthisproblemsolvingexerciseeffective?Hasitbeenverifiedwithafollow-up? YesNo Signature/Title/Date Findings ActionItemTable Actions Implement&VerifyActions Action# Problem Containment/CorrectiveAction HowVerified Action WhoResponsible Planned Actual Status ProblemPeopleMaterialsMachineMethodEnvironmentMeasurementMeasurementEnvironmentMethodMachineMaterialsPeopleWhydiditgetout?Howisitmade?Page1of6http://TheQualityPortal.com