8D - Lean Six Sigma Glossary

The 8D or Eight Disciplines of Problem Solving Method is a structured problem-solving approach. Ford Motor Company developed this method in 1987. It is a structured approach to help teams identify and correct problems, and implement solutions to prevent recurrence.

The 8D process consists of below eight stages:

Establish a team
Describe the problem
Establish the root cause
Establish a corrective action
Verify the corrective action
Implement the corrective action
Establish preventive action
Recognize the team’s efforts

By following this structured approach of 8D, teams can ensure that problems are thoroughly understood and addressed in a comprehensive and timely manner. This method also emphasises on the importance of documenting the problem and the solution. Such documentation helps prevent future recurrences and provide a knowledge base for continuous improvement.

Objectives of steps in 8D

Each stage in 8D has a specific focus and set of objectives as described below.

Establish a Team

The first step in the 8D process is to establish a cross-functional team. This team is responsible for identifying and addressing the problem at hand. The team should include representatives from all relevant departments, such as engineering, quality, and production. It should also include key stakeholders such as customers or suppliers.

Describe the Problem

The second step is to clearly describe the problem in terms of customer requirements and expectations. The team should define the problem in measurable terms, such as a reduction in quality or an increase in costs. They should also establish the scope and impact of the problem.

Establish the Root Cause

The third step is to identify the root causes of the problem by using techniques such as the 5 Whys or Fishbone diagrams. This step is critical in identifying the underlying cause of the problem, rather than just treating the symptoms.

Establish a Corrective Action

The fourth step is to develop and plan a corrective action to address the identified root causes of the problem. The team should determine the most appropriate course of action, based on the findings from the previous steps. And develop a detailed plan for implementation of these corrective actions.

Verify the Corrective Action

The fifth step is to verify the effectiveness of the corrective action. The team should do this by monitoring the results to ensure that it addresses the root cause of the problem. If the corrective action is not effective, the team should return to step 4 to develop and implement a new plan.

Implement the Corrective Action

The sixth step is to implement the corrective action plan in a timely manner, ensuring that it is fully integrated into the process and that the necessary changes are made to prevent the problem from recurring.

Establish Preventive Action

The seventh step is to establish preventive actions that will prevent the problem from recurring in the future. This may include changes in process design, improved training, or the implementation of quality control techniques.

Recognise the Team’s Efforts

The final step is to recognize the efforts of the team, and to document the problem and the solution in order to prevent future recurrences and provide a knowledge base for continuous improvement.

Benefits of 8D

The 8D process provides a systematic and organized approach to solving problems, and ensures that all relevant issues are addressed in a comprehensive and timely manner. The process is effective in identifying the root cause of problems, developing and implementing corrective and preventive actions and provides a framework for continuous improvement. It also emphasizes on the importance of communication, documentation, and teamwork. By following the 8D process, organizations can improve their processes and performance, and provide higher quality products and services to their customers.

The 8D process is widely used in various industries and manufacturing processes and is a recognized standard for problem-solving and quality management. The 8D process is also compatible with other problem-solving and quality management methodologies, such as Six Sigma and Lean. 8D is not only useful to solve problems but also provides a mechanism to gain insights into how to improve the process to prevent the same problem or similar problem to happen again.

By the way, do check out the Certified Lean Six Sigma Black Belt Handbook – it is one of the most essential guide for anyone trying to get certified as LSS Black belt or in general wants to understand LSS and improve processes. – check it out here.

Summary

The 8D method is a comprehensive and effective problem-solving approach that was developed at Ford Motor Company in 1987. It is a structured, step-by-step process that enables teams to identify, correct, and prevent problems, leading to process improvement and achieving customer satisfaction. It provides a mechanism for effective problem-solving, not only by resolving the current issues but also by preventing recurrence and promoting continuous improvement. Organizations can use 8D as a standard framework for problem-solving and quality management to improve their performance, quality and customer satisfaction. This process is simple, straightforward and efficient in providing teams the necessary tools and guidance to achieve the ultimate goal of efficient problem resolution, both in short and long terms.

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Sachin Naik

Passionate about improving processes and systems | Lean Six Sigma practitioner, trainer and coach for 14+ years consulting giant corporations and fortune 500 companies on Operational Excellence | Start-up enthusiast | Change Management and Design Thinking student | Love to ride and drive