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8D Problem Solving - Automotive Industry

Introduction to 8D problem solving methodology.

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8D Problem Solving - Automotive Industry

  1. 1. 8D Problem Solving<br />Automotive Industry<br />
  2. 2. Introduction<br />2 words would summarize<br />this presentation :<br /> Gemba (現場) <br />8D<br />
  3. 3. Introduction<br />Gemba (現場)<br />« Actual location of the issue »<br />
  4. 4.
  5. 5. Gemba Attitude<br />
  6. 6. 8D <br />= 8 Do <br />= 8 Disciplines <br />= 8 Steps<br />
  7. 7. 8D: <br />Systemic problem solving <br /> methodology, introduced <br /> by Ford Motor Company <br /> late 80’s<br />
  8. 8. Do 1:<br />Establish a team<br />
  9. 9. As soon as a customer claim is received, establish <br />a multi-skilled team<br />
  10. 10. Multi-skilled:<br />Quality, Process Engineering,<br />Production Engineering, <br />R&D, Lab<br />
  11. 11. And most important:<br />a line member<br />
  12. 12. Do 2:<br />Define the problem<br />
  13. 13. « A problem well stated is a problem half solved »<br />
  14. 14. WWWWWH:<br />Who, What, Where, When, Why, How<br />
  15. 15. Pareto<br />Also called 80-20 rule<br />
  16. 16. Support your problem description<br />by a picture or a sketch<br />
  17. 17. Gemba :<br />Recover as much as required defective parts<br />
  18. 18. Duplication Tests:<br />Try to reproduce the issue<br />
  19. 19. Red Rabbit :<br />Pass the defective part through the process<br />
  20. 20. Do 3:<br />Implement Containment<br />
  21. 21. Containment consist in stopping the bleeding…<br />
  22. 22. … through stock sorting<br />
  23. 23. … rework,<br />
  24. 24. … enhanced end of line check, etc.<br />
  25. 25. Once containment is agreed among the team, …<br />
  26. 26. It is necessary to validate it:<br />FMEA, Function, Durability, etc<br />
  27. 27. Once validated, implementation follows steps …<br />
  28. 28. Step 1 : Implement at<br />Customer side of the line<br />
  29. 29. Step 2 : Implement at<br />customer stocks<br />
  30. 30. Step 3 : Implement at<br />supplier (your) stock<br />
  31. 31. Step 4 : Implement at<br />your End Of Line<br />
  32. 32. Step 5 : <br />Include containment into<br />manufacturing process<br />
  33. 33. Do 4:<br />Identify root cause<br />
  34. 34. Make sure you<br />are looking for<br />root-cause !<br />
  35. 35. Most known example<br />is engine oil level issue …<br />
  36. 36. … instead of looking for oil leakage underneath the vehicle, member just add oil !<br />
  37. 37. Few methods would support your root-cause analysis …<br />
  38. 38. Ishikawa:<br />Cause-Effect Diagram, 6M, Fishbone Diagram<br />Machines<br />Methods<br />Materials<br />Measurement<br />Personnel<br />Environment<br />
  39. 39. 5 why’s :<br />Ask as much as required the question « Why ?»<br />
  40. 40. Failure Tree Analysis (FTA)<br />
  41. 41. Reverse Engineering:<br />Part by part disassembly until identifying root-cause<br />
  42. 42. Do 5:<br />Choose and verify Permanent Corrective Actions (PCAs)<br />
  43. 43. Once root-cause identified,<br />
  44. 44. PCAs are agreed within the team…<br />
  45. 45. Once again, validation is a must:<br />FMEA, Function, Durability, etc<br />
  46. 46. Do 6:<br />Implement PCAs<br />
  47. 47. Implementation<br />= Project Management<br />
  48. 48. Do 7:<br />Prevent recurrence<br />
  49. 49. Identify lessons learned<br />
  50. 50. Update procedures & documents<br />
  51. 51. Including DFMEA and Control Plan<br />Update procedures & documents<br />
  52. 52. #8<br />Congratulate the team!<br />
  53. 53. Tips & Tricks before<br />Conclusion<br />
  54. 54. Tips & Tricks before<br />Conclusion<br />Speak with facts ! <br />
  55. 55. Tips & Tricks before<br />Conclusion<br />Don’t judge. Don’t blame.<br />
  56. 56. Tips & Tricks before<br />Conclusion<br /> ( Visualize )<br /> ( Visualize)<br />
  57. 57. Tips & Tricks before<br />Conclusion<br />Example of<br />visualization<br />
  58. 58. Tips & Tricks before<br />Conclusion<br />Example of visualization<br />
  59. 59. Tips & Tricks before<br />Conclusion<br />Example of<br />visualization<br />
  60. 60. Conclusion<br />Conclusion<br />
  61. 61. Conclusion<br />Gemba = A mindset<br />8D = A discipline<br />
  62. 62. Thank you for your attention<br />Thank you for your attention<br />
  63. 63. More ressources on :<br />http://gestionprojetauto.wordpress.com<br /><ul><li>Articles
  64. 64. Videos
  65. 65. Free templates
  66. 66. Favourite Automotive Links</li></li></ul><li>Share this presentation<br />
  67. 67. Available Trainings<br />Project Management<br />Problem Solving Methodology (8D)<br />Functional Analysis<br />Design FMEA (DFMEA)<br />
  68. 68. Imad Tamir - イマヅ タミル<br />Automotive Project Management : Training, Coaching<br /><ul><li>imad.tamir@gmail.com</li></ul>(c) Copyright 2009-2010<br />

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