Effective 8D
Effective 8D
Effective 8D
8Ds
Understanding Problems
Variation
Off-Target
X
XXX X
X
XX
X
X
X
X
X
X
X
X
X
X
X
On-Target
Center
Process
XXX
XXX
XXX X
X XX X
X
X
X
Reduce
Spread
Understanding Problems
Large
Off-Target
Variation
LSL
LSL
USL
USL
On-Target
Center
Process
Reduce
Spread
LSL
USL
Understanding Problems
Problem :
A Question posed for a solution, decision or determination.
A proposition requiring some operation to be performed.
Practical Problem
Need
Low yield ?
Do
Statistical Problem
Need
Do
Statistical Solution
Need
Do
Practical Solution
Need
Understanding Problems
Common Cause Variation
Source of variation which affects all individual
values of a process; Random in nature.
E.g. Ambient temperature; general vibrations in lathe;
etc.
Understanding Problems
Perception
Special Cause Common Cause
Special Cause
In Control
Inaction /
Out of control
Truth
Over adjustment/
Common Cause Out of control
In Control
2 Dimensions in Solving
Problems
6 sigma
SPC
tools
Auto
controls
First/Last off
Common
SPC
Special
Type of Cause
Escape root cause - What caused the bad part to slip past
Supplier place to the Customer plant?
Choose PCA
80% of the 8Ds lack link between root cause and PCA !!
Verify PCA
Validate PCA
Validate PCA
Pre-customer Validation is ongoing evidence (data) - before exposure to
the customer and following successful Verification - that the implemented
action is still doing what was intended without introducing a new problem.
Validation activities may include tests,inspections, observations and
other quality checks performed on production product using the
specified production process.
These tests, etc., are correlated to the customer's symptom and are
good indicators of action effectiveness.
Customer Validation is ongoing evidence (data) - received from the
customer - that the action taken to eliminate the customer's symptom is still
working.
Confirmation is obtained by monitoring the same indicator that
demonstrated the symptom initially.
Performance results of the indicator may be tracked using the
Paynter Chart.
Prevent Recurrence
This is the toughest part!!
We tend to relax once the problem disappears
momentarily.
Document the corrective actions in FMEA /
Control plans / Operator Instructions.
Read across to similar product / process lines
Redefine Standards based on lessons learnt.
Control plans
Process control
Product inspection
Sampling size
Frequency
Default is 5 pcs every hour