8D Problem Solving Software

8D (8 Disciplines) Problem Solving Method

Solving problems using 8D (8 Disciplines) is a method developed for the US Army in the 1970s, later adapted by the Ford Motor Company for the production usage. Used to solve problems, it is now used by many quality engineers in factories all over the world.

8D is applicable in many areas of the factory's operation, and is particularly suitable for: handling complaints, reducing the amount of waste, mitigating the impact of potentially hazardous situations, as well as any other problems occurring in and around production. The 8D method can also be used in your personal life, but it is not the scope of this study.

Over time, 8D has become a standard in the automotive, assembly and other manufacturing industries that require a detailed structured problem-solving process using a team-based approach.

This extremely simple, yet effective method determines continuous corrective actions based on a statistical analysis of the problem and its source by identifying root causes. 8D, like PDCA, can be implemented cyclically according to the logic of Deming Cycle, especially in the case when it was applied for implementing continuous improvement.

Originally an eight-step action plan (hence the name "8D"), it is often supplemented with the so-called step 0, i.e. immediate actions. The steps of the 8D Problem Solving method are as follows:

1. Immediate actions [0D] - implementation of emergency actions that will be launched as soon as a problem occurs or is identified, e.g. stopping the line, suspending shipments or ordering additional selection.
2. Forming the team [1D] - determining the competencies necessary to solve the problem and gathering an interdisciplinary team of specialists who look at the problem from different points of view.
3. Problem identification [2D] - clarifying and understanding the problem and defining its negative impact. You can use one of the tools that help define the problem, for example: 5W2H, 5-Whys or Ishikawa Diagram (Fishbone Diagram).
4. Temporary corrective actions [3D] - temporary corrective actions that should be carried out to isolate the problem from other areas or customers. These activities focus on the elimination of negative effects, not the root cause of the problem.
5. Root cause analysis [4D] - activities and analyzes carried out within the entire team, aimed at finding the root cause of the problem. In this step, tools such as 5-Whys or the Ishikawa Diagram (Fishbone Diagram) will be useful even more than in 2D.
6. Permanent corrective actions [5D] - actions aimed at eliminating the cause of the problem, not just negative effects (symptoms). It is worth implementing one corrective action for one cause at the time. Otherwise, it might be difficult to determine what the real cause of the problem was.
7. Corrective action verification [6D] - actions related to checking whether the corrective actions have brought the intended effect and whether new problems have arisen in other areas of the factory's operation as a result, both in the short and long term.
8. Preventive actions [7D] - actions carried out to prevent similar problems in the future. These actions should go beyond the source of the problem and can be applied across the organization, to all areas and to a wider extent.
9. Summary, conclusions and appreciation [8D] - after completing the activities described previously, make summaries, draw conclusions for the future, and thank the entire team for their commitment and efforts in successfully solving the problem.

Action Plan software includes a number of features and resources to successfully apply 8D to factory problem solving.

• The Action Plan Template Library also includes a template called "8D Problem Solving" that defines a complete 9 step action plan with how to descriptions, assigned responsible people and deadlines for carrying out individual steps.
• Two views of the implementation of the action plan - tabular view and Gantt - provide many functions to improve work in a multi-departmental team appointed to solve the problem: comments, escalations, official orders or requesting an action transfer are just some of them.
• As a user, you have at your disposal the Action Plan internet platform and the Action Plan Pulse mobile application. Thanks to this, you can take actions related to solving the problem with the 8D method both from the computer and from the phone.
• The software includes the so-called "controls" function so that you can schedule the performance verification (step 6D) without pausing the 8D plan run. You can schedule any number of checks for any future date.
• By using the tagging function of action plans, as well as attaching documentation in the form of XLSX, DOCX, PDF and other files like graphics, you create a knowledge base on the existing problems, causes and solutions. The knowledge gathered in the database will contribute to the efficient solving of problems in the future.
• Often times, the innovative ideas of team members are a side effect of problem solving brainstorming sessions. Action Plan also includes the Quick Kaizen module for collecting, evaluating and implementing ideas as part of a continuous improvement process.