8D is the most common root cause analysis language used between OEM customers to Tier 1 suppliers.  This course is developed and taught by one of the top experts in 8D.  He was one of the original participants in the first TOPS/8D course taught at Ford Motor Company in 1987.  The John Lindland was the lead applied statistics expert for the Ford Electronic Division supply base.  He was part of the Supplier Quality Assurance department.  He worked with all suppliers who had existing problems of significance.  In this role he applied these methods, along with design of experiments and applied statistics.  John was one of the first Ford employees who learned this method.  He has applied the methods successfully for over 30 years.  Learn to apply 8D quickly and effectively.

Global 8D is applied for complex problems when the causes are not obvious.  Global 8D is not used on a process when the process has not be established.  Global 8D is not applied to a product design when the product design has not been established (e.g. development).  8D requires a stable structure.  Solutions change the process or product design.  Preventions improve process and product controls so the root cause is not redesigned into future designs.  Preventions manage the process and control inputs, process settings, preventive maintenance, and predictive maintenance.  8D is used when problems have causes which are not obvious or cannot be identified with simple methods.  OEM customers require suppliers to respond Supplier Corrective Action Requests (SCARs) with an 8D.

Overview

• The history of 8D
• The four countermeasures to risk
• Scope of applicability

D0: Prepare for Problem Solving

• Problem qualification
• Emergency Response Action

D1: Effective Teams

• Types of problems and their team members
• Team building

D2: Problem Description

• Process flow diagram
• Trend Charts
• Pareto Charts
• Is/Is-not analysis

D3: Interim Corrective Action (ICA) and Verification

• Escape point analysis
• ICA selection matrix

D4: Root Cause Analysis and Verification

• 7FM Design Root Cause Analysis Models
• 7FM Process Root Cause Analysis Models
• Fishbone Diagram
• Cause and Effect Matrix
• Designed Experiments and Statistics

D5: Permanent Corrective Action and Verification

• Product Design Changes
• Process Design Changes
• PCA Decision Matrix

D6: Implement and Verify PCA

• Project Management
• Trend Charts
• Pareto Charts

D7: Preventive Actions

• 7FM FMEA
• Escape Point Monitoring and Controls
• Updating QM, Design, and Process reference guidelines

D8: Team Recognition