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8D Report and template

8D Report - Toolshero

8D Report: this article explains the 8D Report in a practical way. Besides the explanation of what this concept is, we also the 8 disciplines and the importance of teamwork. Next to that we also provide a template to get strated. Enjoy reading!

What is an 8D Report? The meaning

The 8D Report or 8d corrective action report is a problem-solving approach for product and process improvement. Furthermore, 8D Methodology is used to implement structural long-term solutions to prevent recurring problems. The 8D Report was first used in the automotive industry.

During World War II the 8D Method was used in Team Oriented Problem Solving (TOPS) in the United States under Military Standard 1520. It was later used and popularized by car manufacturer Ford .

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In the 1990s Ford continued to develop the 8D process as a result of which the process is said to have found its origin in the automotive industry. Today, the 8D Method can be used to write formal reports and it can be applied as a working and thinking method for smaller problems.

The 8D Report is also used as a means of communication within companies, which makes the problem solving method transparent and can therefore be applied to the entire production chain. The 8D method is also known as: Global 8D , Ford 8D or TOPS 8D .

8D Report: eight disciplines

The 8D Methodology mainly focuses on solving problems and comprises 8 steps or disciplines. It helps quality control staff find the root cause of problems within a production process in a structured manner so that they can resolve the problem(s).

In addition, it helps implement product or process improvements, which can prevent problems. The 8D Report is about mobilizing a good team that has sufficient expertise and experience to solve or prevent problems. The 8D Report consists of 8 disciplines that describe corrective measures based on the statistical analysis of the problem. This results in the following eight process steps:

8D Report disciplines - Toolshero

Figure 1 – 8D report: the eight disciplines

D1 – Create a team

Mobilizing a good team is essential. The team must preferably be multidisciplinary. Due to a varied combination of knowledge, skills and experience, one can look at a problem from different perspectives.

Besides having an effective team leader, it is also advisable to record team structure, goals, different team roles, procedures and rules in advance so that the team can begin taking action quickly and effectively, and there is no room for misunderstandings.

D2 – Describe the problem

Define the problem as objectively as possible. The 5W2H analysis (who, what, when, where, why, how, how much) is a welcome addition to the problem analysis and can help to arrive at a clear description of the problem.

D3 – Interim containment action

It may be necessary to implement temporary fixes. For example, to help or meet a customer quickly or when a deadline has to be met. It is about preventing a problem from getting worse until a permanent solution is implemented.

D4 – Identify the root cause

Before a permanent solution is found, it is important to identify all possible root causes that could explain why the problem occurred. Various methods can be used for this purpose, such as the fishbone diagram (Ishikawa) which considers factors such as people, equipment, machines and methods or the 5 whys method.

All causes must be checked and/ or proven and it is good to check why the problem was not noticed at the time it occurred.

Take a look at our article on Root Cause Analysis , a method of problem solving that aims at identifying the root causes of problems or incidents.

D5 – Developing permanent corrective actions

As soon as the root cause of the problem has been identified, it is possible to search for the best possible solution. Again various problem solving methods can be used such as value analysis and creative problem solving.

From here, permanent corrective actions can be selected and it must be confirmed that the selected corrective actions will not cause undesirable side effects. It is therefore advisable to define contingency actions that will be useful in unforeseen circumstances.

D6 – Implementing permanent corrective actions

As soon as the permanent corrective actions are identified, they can be implemented. By planning ongoing controls, possible underlying root causes are detected far in advance.

The long term effects should be monitored and unforeseen circumstances should be taken into account.

D7 – Preventive measures

Prevention is the best cure. This is why additional measures need to be taken to prevent similar problems. Preventative measures ensure that the possibility of recurrence is minimised. It is advisable to review management systems, operating systems and procedures, so that they can be improved procedures if necessary.

D8 – Congratulate the team

By congratulating the team on the results realized, all member are rewarded for their joint efforts. This is the most important step within the 8D method; without the team the root cause of the problem would not have been found and fixed.

By putting the team on a pedestal and sharing the knowledge throughout the organization, team motivation will be high to solve a problem the next time it presents itself.

The 8D Report is also about teamwork

A strength of this method is its focus on teamwork. The team as a whole is believed to be better and smarter than the sum of the qualities of the individuals. Not every problem justifies or requires the 8D Report.

Furthermore, the 8D Report is a fact-based problem solving process, which requires a number of specialized skills, as well as a culture of continuous improvement. It could be that training of the team members is required before 8D can work effectively within an organization.

The team must recognize the importance of cooperation in order to arrive at the best possible solution for implementation.

8D Report template

Ready to start with the 8D problem-solving approach? Start describing the different disciplines of 8D with this 8D Report template.

Download the 8D Report template

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It’s Your Turn

What do you think? Can you apply the 8D Report in today’s modern business companies? Do you recognize the practical explanation or do you have more suggestions? What are your success factors for problem analysis and problem solving?

Share your experience and knowledge in the comments box below.

More information

  • Behrens, B. A., Wilde, I., & Hoffmann, M. (2007). Complaint management using the extended 8D-method along the automotive supply chain . Production Engineering, 1(1), 91-95.
  • Krajnc, M. (2012). With 8D method to excellent quality . RUO. Revija za Univerzalno Odlicnost, 1(3), 118.
  • Possley, M. (2016). 8D Team Based Problem Solving – 2nd Edition: An Instructive Example . CreateSpace Independent Publishing Platform

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Anneke Kuijk

Anneke Kuijk

Anneke Kuijk is a text writer who has the qualities to analyze information and to extract the core message. This converts them into understandable and readable texts. In addition to writing content, she is also active as a teacher (language) integration and in many ways active with language.

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3 responses to “8d report and template”.

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Nice information it is very useful

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What stands for D in 8D…?

8d problem solving report example

The D in 8D stands for 8 Disciplines / Eight Disciplines.

Kind regards, Tom

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Eight Disciplines of Problem Solving (8D)

– Eight Disciplines of Problem Solving –

⇓   Introduction to 8D

⇓   What is 8D

⇓   Why Apply 8D

⇓   When to Apply 8D

⇓   How to Apply 8D

Quality and Reliability Support | Quality-One

Introduction to Eight Disciplines of Problem Solving (8D)

The Eight Disciplines of Problem Solving (8D) is a problem solving methodology designed to find the root cause of a problem, devise a short-term fix and implement a long-term solution to prevent recurring problems. When it’s clear that your product is defective or isn’t satisfying your customers, an 8D is an excellent first step to improving Quality and Reliability.

Ford Motor Company developed this problem solving methodology, then known as Team Oriented Problem Solving (TOPS), in the 1980s. The early usage of 8D proved so effective that it was adopted by Ford as the primary method of documenting problem solving efforts, and the company continues to use 8D today.

8D has become very popular among manufacturers because it is effective and reasonably easy to teach. Below you’ll find the benefits of an 8D, when it is appropriate to perform and how it is performed.

What is Eight Disciplines of Problem Solving (8D)

The 8D problem solving process is a detailed, team oriented approach to solving critical problems in the production process. The goals of this method are to find the root cause of a problem, develop containment actions to protect customers and take corrective action to prevent similar problems in the future.

The strength of the 8D process lies in its structure, discipline and methodology. 8D uses a composite methodology, utilizing best practices from various existing approaches. It is a problem solving method that drives systemic change, improving an entire process in order to avoid not only the problem at hand but also other issues that may stem from a systemic failure.

8D has grown to be one of the most popular problem solving methodologies used for Manufacturing, Assembly and Services around the globe. Read on to learn about the reasons why the Eight Disciplines of Problem Solving may be a good fit for your company.

8D - Problem Solving Format

Why Apply Eight Disciplines of Problem Solving (8D)

The 8D methodology is so popular in part because it offers your engineering team a consistent, easy-to-learn and thorough approach to solving whatever problems might arise at various stages in your production process. When properly applied, you can expect the following benefits:

  • Improved team oriented problem solving skills rather than reliance on the individual
  • Increased familiarity with a structure for problem solving
  • Creation and expansion of a database of past failures and lessons learned to prevent problems in the future
  • Better understanding of how to use basic statistical tools required for problem solving
  • Improved effectiveness and efficiency at problem solving
  • A practical understanding of Root Cause Analysis (RCA)
  • Problem solving effort may be adopted into the processes and methods of the organization
  • Improved skills for implementing corrective action
  • Better ability to identify necessary systemic changes and subsequent inputs for change
  • More candid and open communication in problem solving discussion, increasing effectiveness
  • An improvement in management’s understanding of problems and problem resolution

8D was created to represent the best practices in problem solving. When performed correctly, this methodology not only improves the Quality and Reliability of your products but also prepares your engineering team for future problems.

When to Apply Eight Disciplines of Problem Solving (8D)

The 8D problem solving process is typically required when:

  • Safety or Regulatory issues has been discovered
  • Customer complaints are received
  • Warranty Concerns have indicated greater-than-expected failure rates
  • Internal rejects, waste, scrap, poor performance or test failures are present at unacceptable levels

How to Apply Eight Disciplines of Problem Solving (8D)

The 8D process alternates inductive and deductive problem solving tools to relentlessly move forward toward a solution. The Quality-One approach uses a core team of three individuals for inductive activities with data driven tools and then a larger Subject Matter Expert (SME) group for the deductive activities through brainstorming, data-gathering and experimentation.

D0: Prepare and Plan for the 8D

Proper planning will always translate to a better start. Thus, before 8D analysis begins, it is always a good idea to ask an expert first for their impressions. After receiving feedback, the following criterion should be applied prior to forming a team:

Collect information on the symptoms

Use a Symptoms Checklist to ask the correct questions

Identify the need for an Emergency Response Action (ERA), which protects the customer from further exposure to the undesired symptoms

D1: Form a Team

A Cross Functional Team (CFT) is made up of members from many disciplines. Quality-One takes this principle one step further by having two levels of CFT:

  • The Core Team Structure should involve three people on the respective subjects: product, process and data
  • Additional Subject Matter Experts are brought in at various times to assist with brainstorming, data collection and analysis

Teams require proper preparation. Setting the ground rules is paramount. Implementation of disciplines like checklists, forms and techniques will ensure steady progress.  8D must always have two key members: a Leader and a Champion / Sponsor:

  • The Leader is the person who knows the 8D process and can lead the team through it (although not always the most knowledgeable about the problem being studied)
  • The Champion or Sponsor is the one person who can affect change by agreeing with the findings and can provide final approval on such changes

D2: Describe the Problem

The 8D method’s initial focus is to properly describe the problem utilizing the known data and placing it into specific categories for future comparisons. The “Is” data supports the facts whereas the “Is Not” data does not. As the “Is Not” data is collected, many possible reasons for failure are able to be eliminated. This approach utilizes the following tools:

  • Problem Statement
  • Affinity Diagram (Deductive tool)
  • Fishbone/Ishikawa Diagram (Deductive tool)
  • Problem Description

D3: Interim Containment Action

In the interim, before the permanent corrective action has been determined, an action to protect the customer can be taken. The Interim Containment Action (ICA) is temporary and is typically removed after the Permanent Correct Action (PCA) is taken.

  • Verification of effectiveness of the ICA is always recommended to prevent any additional customer dissatisfaction calls

D4: Root Cause Analysis (RCA) and Escape Point

The root cause must be identified to take permanent action to eliminate it. The root cause definition requires that it can be turned on or off, at will. Activities in D4 include:

  • Comparative Analysis listing differences and changes between “Is” and “Is Not”
  • Development of Root Cause Theories based on remaining items
  • Verification of the Root Cause through data collection
  • Review Process Flow Diagram for location of the root cause
  • Determine Escape Point, which is the closest point in the process where the root cause could have been found but was not

D5: Permanent Corrective Action (PCA)

The PCA is directed toward the root cause and removes / changes the conditions of the product or process that was responsible for the problem. Activities in D5 include:

  • Establish the Acceptance Criteria which include Mandatory Requirements and Wants
  • Perform a Risk Assessment /  Failure Mode and Effects Analysis (FMEA) on the PCA choices
  • Based on risk assessment, make a balanced choice for PCA
  • Select control-point improvement for the Escape Point
  • Verification of Effectiveness for both the PCA and the Escape Point are required

D6: Implement and Validate the Permanent Corrective Action

To successfully implement a permanent change, proper planning is essential. A project plan should encompass: communication, steps to complete, measurement of success and lessons learned. Activities in D6 include:

  • Develop Project Plan for Implementation
  • Communicate the plan to all stakeholders
  • Validation of improvements using measurement

D7: Prevent Recurrence

D7 affords the opportunity to preserve and share the knowledge, preventing problems on similar products, processes, locations or families. Updating documents and procedures / work instructions are expected at this step to improve future use. Activities in D7 include:

  • Review Similar Products and Processes for problem prevention
  • Develop / Update Procedures and Work Instructions for Systems Prevention
  • Capture Standard Work / Practice and reuse
  • Assure FMEA updates have been completed
  • Assure Control Plans have been updated

D8: Closure and Team Celebration

Teams require feedback to allow for satisfactory closure. Recognizing both team and individual efforts and allowing the team to see the previous and new state solidifies the value of the 8D process. Activities in D8 include:

  • Archive the 8D Documents for future reference
  • Document Lessons Learned on how to make problem solving better
  • Before and After Comparison of issue
  • Celebrate Successful Completion

8D - D0 Reference Card

8D and Root Cause Analysis (RCA)

The 8D process has Root Cause Analysis (RCA) imbedded within it. All problem solving techniques include RCA within their structure. The steps and techniques within 8D which correspond to Root Cause Analysis are as follows:

  • Problem Symptom is quantified and converted to “Object and Defect”
  • Problem Symptom is converted to Problem Statement using Repeated Whys
  • Possible and Potential Causes are collected using deductive tools (i.e. Fishbone or Affinity Diagram)
  • Problem Statement is converted into Problem Description using Is / Is Not
  • Problem Description reduces the number of items on the deductive tool (from step 3)
  • Comparative Analysis between the Is and Is Not items (note changes and time)
  • Root Cause theories are developed from remaining possible causes on deductive tool and coupled with changes from Is / Is Not
  • Compare theories with current data and develop experiments for Root Cause Verification
  • Test and confirm the Root Causes

Is Is Not Example

Example: Multiple Why Technique

The Multiple / Repeated Why (Similar to 5 Why) is an inductive tool, which means facts are required to proceed to a more detailed level. The steps required to determine problem statement are:

  • Problem Symptom is defined as an Object and Defect i.e. “Passenger Injury”
  • Why? In every case “SUV’s Roll Over”
  • Why? In every case, it was preceded by a “Blown Tire”
  • Why? Many explanations may be applied, therefore the team cannot continue with another repeated why past “Blown Tire”
  • Therefore, the Problem Statement is “Blown Tire”
  • Why? Low (Air) Pressure, Tire Defect (Degradation of an Interface) and High (Ambient) Temperature
  • Counter measures assigned to low pressure and tire defect

This example uses only 4 of the 5 Whys to determine the root causes without going further into the systemic reasons that supported the failure. The Repeated Why is one way to depict this failure chain. Fault Tree Analysis (FTA) could also be used.

3 Legged 5 Why

Learn More About Eight Disciplines of Problem Solving (8D)

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Article • 8 min read

8D Problem Solving Process

Solving major problems in a disciplined way.

By the Mind Tools Content Team

(Also known as Global 8D Problem Solving)

8d problem solving report example

When your company runs into a major problem, you need to address it quickly. However, you also need to deal with it thoroughly and ensure that it doesn't recur – and this can take a lot of effort and elapsed time.

The 8D Problem Solving Process helps you do both of these seemingly-contradictory things, in a professional and controlled way. In this article, we'll look at the 8D Problem Solving Process, and we'll discuss how you can use it to help your team solve major problems.

Origins of the Tool

The Ford Motor Company® developed the 8D (8 Disciplines) Problem Solving Process, and published it in their 1987 manual, "Team Oriented Problem Solving (TOPS)." In the mid-90s, Ford added an additional discipline, D0: Plan. The process is now Ford's global standard, and is called Global 8D.

Ford created the 8D Process to help teams deal with quality control and safety issues; develop customized, permanent solutions to problems; and prevent problems from recurring. Although the 8D Process was initially applied in the manufacturing, engineering, and aerospace industries, it's useful and relevant in any industry.

The eight disciplines are shown in figure 1, below:

Figure 1: The 8D Problem Solving Process

8d problem solving report example

The 8D Process works best in teams tasked with solving a complex problem with identifiable symptoms. However, you can also use this process on an individual level, as well.

Applying the Tool

To use the 8D Process, address each of the disciplines listed below, in order. Take care not to skip steps, even when time is limited; the process is only effective when you follow every step.

Discipline 0: Plan

Before you begin to assemble a team to address the problem, you need to plan your approach. This means thinking about who will be on the team, what your time frame is, and what resources you'll need to address the problem at hand.

Discipline 1: Build the Team

You should aim to put together a team that has the skills needed to solve the problem, and that has the time and energy to commit to the problem solving process.

Keep in mind that a diverse team is more likely to find a creative solution than a team of people with the same outlook (although if outlooks are too diverse, people can spend so much time disagreeing that nothing gets done).

Create a team charter that outlines the team's goal and identifies each person's role. Then, do what you can to build trust and get everyone involved in the process that's about to happen.

If your team is made up of professionals who haven't worked together before, consider beginning with team-building activities to ensure that everyone is comfortable working with one another.

Discipline 2: Describe the Problem

Once your team has settled in, describe the problem in detail. Specify the who, what, when, where, why, how, and how many; and use techniques like CATWOE and the Problem-Definition Process to ensure that you're focusing on the right problem.

Start by doing a Risk Analysis – if the problem is causing serious risks, for example, to people's health or life, then you need to take appropriate action. (This may include stopping people using a product or process until the problem is resolved.)

If the problem is with a process, use a Flow Chart , Swim Lane Diagram , or Storyboard to map each step out; these tools will help your team members understand how the process works, and, later on, think about how they can best fix it.

Discovering the root cause of the problem comes later in the process, so don't spend time on this here. Right now, your goal is to look at what's going wrong and to make sure that your team understands the full extent of the problem.

Discipline 3: Implement a Temporary Fix

Once your team understands the problem, come up with a temporary fix. This is particularly important if the problem is affecting customers, reducing product quality, or slowing down work processes.

Harness the knowledge of everyone on the team. To ensure that each person's ideas are heard, consider using brainstorming techniques such as Round Robin Brainstorming or Crawford's Slip Writing Method , alongside more traditional team problem solving discussions.

Once the group has identified possible temporary fixes, address issues such as cost, implementation time, and relevancy. The short-term solution should be quick, easy to implement, and worth the effort.

Discipline 4: Identify and Eliminate the Root Cause

Once your temporary fix is in place, it's time to discover the root cause of the problem.

Conduct a Cause and Effect Analysis to identify the likely causes of the problem. This tool is useful because it helps you uncover many possible causes, and it can highlight other problems that you might not have been aware of. Next, apply Root Cause Analysis to find the root causes of the problems you've identified.

Once you identify the source of the problem, develop several permanent solutions to it.

If your team members are having trouble coming up with viable permanent solutions, use the Straw Man Concept to generate prototype solutions that you can then discuss, tear apart, and rebuild into stronger solutions.

Discipline 5: Verify the Solution

Once your team agrees on a permanent solution, make sure that you test it thoroughly before you fully implement it, in the next step.

  • Conducting a Failure Mode and Effects Analysis (FMEA) to spot any potential problems.
  • Using Impact Analysis to make sure that there will be no unexpected future consequences.
  • Using Six Thinking Hats to examine the fix from several different emotional perspectives.

Last, conduct a Blind Spot Analysis to confirm that you and your team haven't overlooked a key factor, or made an incorrect assumption about this solution.

Discipline 6: Implement a Permanent Solution

Once your team reaches a consensus on the solution, roll your fix out. Monitor this new solution closely for an appropriate period of time to make sure that it's working correctly, and ensure that there are no unexpected side effects.

Discipline 7: Prevent the Problem From Recurring

When you're sure that the permanent solution has solved the problem, gather your team together again to identify how you'll prevent the problem from recurring in the future.

You might need to update your organization's standards, policies, procedures, or training manual to reflect the new fix. You'll likely also need to train others on the new process or standard. Finally, you'll need to consider whether to change your management practices or procedures to prevent a recurrence.

Discipline 8: Celebrate Team Success

The last step in the process is to celebrate and reward your team's success . Say "thank you" to everyone involved, and be specific about how each person's hard work has made a difference. If appropriate, plan a party or celebration to communicate your appreciation.

Before the team disbands, conduct a Post-Implementation Review to analyze whether your solution is working as you thought, and to improve the way that you solve problems in the future.

In the late 1980s, Ford Motor Company developed the 8D (8 Disciplines) Problem Solving Process to help manufacturing and engineering teams diagnose, treat, and eliminate quality problems. However, teams in any industry can use this problem solving process.

The eight disciplines are:

  • Build the Team.
  • Describe the Problem.
  • Implement a Temporary Fix.
  • Identify and Eliminate the Root Cause.
  • Verify the Solution.
  • Implement a Permanent Solution.
  • Prevent the Problem From Recurring.
  • Celebrate Team Success.

The 8D Problem Solving Process is best used with a team solving complex problems; however, individuals can also use it to solve problems on their own.

Ford is a registered trademark of the Ford Motor Company: https://www.ford.com/

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8D Methodology | Problem Solving Method | Example | Excel

8D Methodology Problem Solving Method Example Excel

What is 8D Methodology?

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Eight Disciplines of Problem Solving:

  • Establish the team
  • Describe the problem
  • Develop interim containment actions
  • Define and verify root cause & escape points
  • Choose and verify permanent corrective actions
  • Implement and validate permanent corrective actions
  • System prevention actions to prevent a recurrence
  • Recognize team contributions

8D Methodology

8D Problem Solving Example:

D1: establish the team:.

8D Problem Solving Training Presentation

D2: Describe the Problem:

D3: develop interim containment actions, d4: define and verify root cause & escape points:, d5: choose and verify permanent corrective actions.

  • Elimination
  • Replacement
  • Facilitation

Six Mistake Proofing Principles

D6: Implement and Validate Permanent Corrective Actions

D7: system prevention action to prevent recurrence, d8: recognize team contributions, related posts, 12 comments.

8d problem solving report example

Very detailed explanation on 8D. Thanks

8d problem solving report example

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Hi, clear and detailed explanation. Thanks for that.Just want to know how to download the excel template. Could you pl support

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8D Manufacturing Report: Your Guide to Effective Problem Solving

  • Written by Brecht Plasschaert
  • Compliance , Lean Manufacturing
  • Updated on January 10, 2024
  • Published on August 16, 2022

Manufacturing companies are the backbone of any economy. They produce goods for local or international markets, employ people, and keep their customers happy. 

That’s why manufacturers often use 8D reports to identify and solve problems before they impact their production and business to ensure the quality of produced goods. The methodology was developed by Toyota Motors Manufacturing (TMM) in Japan in the 1960s to help the company achieve better performance. 

For companies who want to compete with other manufacturers around the world, it’s essential to identify and track root causes of non-conformities or problems in a production environment. This helps them achieve a high level of product efficiency and quality, which translates into lower costs and higher profits. 

In this article we cover the ins and outs of 8D reporting, how to use it, and the advantages it may offer to your workforce.

Download our 8D template as well to make your problem-solving process simpler.

The 8D method structure

The 8D problem-solving method is a systematic approach to problem solving that emphasizes team participation. This method generally covers:

  • Identifying the Problem — You must first identify what is wrong with the process or operation.
  • Determining Causes — After identifying a problem, you will have to determine its root cause(s). This may not be easy, but it’s imperative if you want to fix your processes and prevent future problems from arising again.
  • Developing Corrective Action — Once you’ve identified the causes of your problems and analyzed all possible solutions, it’s time to develop corrective actions. Create a plan for how each possible solution would work (i.e., “if we use this part instead,” or “if we add these people,” etc.). You’ll also need metrics and checkpoints throughout this process to ensure that everything is working as intended.

The 8 disciplines

The eight disciplines (8D) follow a logical sequence of eight steps. It’s one of the most common methods used in manufacturing because it’s a structured approach, but it can also be applied to other industries.

D1: Create a team When using 8D, it is important to have a cross-functional team with individuals from different disciplines to assist you cover more territory. There should be two subgroups for the team members:

  • Core members: people who are more data-driven and typical product, process, and data experts.
  • Subject Matter Experts (SME): members who may contribute to brainstorming, research, and process observation. Bring in fresh SMEs without hesitation to assist with any step of the process.

These team members have to be equipped with the knowledge necessary to identify the issue and implement solutions.

D2: Describe the problem

The problem description is a narrative that describes the issue in detail and should be understood across the team members. It explains how the issue happened, what impact it had on your business, and why you need to fix it. The problem description should include:

  • The underlying causes of your problem (the root cause). Why did this happen?
  • What’s the impact of this issue? How much money are you losing because of this? What other problems does it cause within your company?
  • How will fixing these underlying causes help solve or prevent future issues related to this one?

Here are some techniques and tools to identify and formulate the problems:

  • 5 Why’s formulation
  • Affinity Diagram
  • Fishbone Diagram
  • Is / Is Not method

D3: Develop a containment plan

Once you have identified, isolated, and controlled your manufacturing process problems, it’s time to create a plan for containment. You need clear descriptions so that everyone understands what they’re supposed to do in order to solve this issue. Be aware, an Interim Containment Action (ICA) is a temporary plan and should only be replaced with the Permanent Corrective Action (PCA) after completing 8D.

D4: Root Cause Analysis (RCA) and Escape Point

You might find yourself wandering down several rabbit holes before reaching this point. Be patient and methodical as you work through each step in your investigation process. This process should always be guided by facts rather than assumptions or guesses about what could be going wrong behind closed doors at your company’s factories overseas!

Review your results, then talk with your team about potential causes of the issue. Each probable root cause is mapped to the issue statement and any associated test results as part of the root cause analysis. Be cautious to rule out all probable reasons; hazy brainstorming and careless analysis might lead you to miss important details.

Some methods during this step include:

  • Comparative Analysis
  • Development of Root Cause Theories
  • Verification of Root Cause Theories
  • Review Process Flow Diagrams
  • Determine Escape Points, the closest point in the process where root cause could be found

In addition to determining the underlying causes, attempt to remember when and why you first discovered the issue in the process. This is called an escape point, and there can be more than one.

D5: Formulate Permanent Corrective Actions (PCA)

Corrective actions should be based on the root cause analysis. The first step in formulating corrective actions is to determine the root cause of the failure mode. To do this, you will need to analyze all of your data and identify which potential factors contributed to the problem. Once you have determined what caused the failure, you can then come up with ways of preventing similar failures from occurring in the future.

For example, if an assembly line stops due to an electrical issue with one machine, it would not make sense to fix just one machine; rather, you should look at all machines on that line and make sure they have proper electrical connections so that they are able to function properly.

So when something goes wrong, you will have a plan for fixing it before it causes even bigger problems down the road. There are several steps involved in creating an effective corrective action plan:

  • Plan out how long it will take before implementing any changes that can help fix whatever issue has arisen;
  • Create an actionable plan detailing exactly what needs changing;
  • Check in at regular intervals on progress made toward completing this project so that no one gets forgotten along its path until completion (this includes monitoring by both parties involved)
  • If necessary take appropriate steps like adding more resources or reallocating existing ones when delays  arise from unforeseen factors such as weather conditions etc .”

D6: Implement and Validate the Permanent Corrective Action

Interim measures are temporary solutions to a problem. They can be used to prevent further damage or to allow time for a permanent solution to be implemented. Interim measures can also be used to reduce the impact of the problem until it is solved.

When you have identified an issue in your business, create an action plan that includes interim measures as well as final goals and expectations. If there is some sort of delay in implementing these interim measures, report back on progress at least monthly so management stays up-to-date on what is happening within your department and company at large.

Some activities during the 6D step include:

  • Creating a project plan
  • Share the plan with relevant parties.
  • Use metrics to verify progress

D7: Monitoring of corrective measures

Monitoring is a key part of the 8D method. Monitoring is a way to check if a corrective action is working, or if it needs to be changed or completed. It’s also a way to check if the root cause has been addressed, and if your company has learned anything new from the incident that could help prevent future errors.

Your team needs to retain and document the shared knowledge that was gained while identifying, resolving, and preventing this problem. It’s important to review existing documents or procedures and update them accordingly to improve future outcomes.

Activities you need to keep in mind during this step are:

  • Reviewing comparable products and procedures to avoid other problems.
  • Creating or updating work instructions and procedures.
  • Capturing new industry standards and procedures.
  • Confirming the most recent failure mode and effect analysis (FMEA).
  • Confirming the revision of control plans.

D8: Recognize team and individual efforts

Giving feedback to ensure a good outcome is crucial for any team to flourish. Recognize the efforts and labor that each person has put into what they have brought to the process at this moment.

The tasks in this stage consist of:

  • Archive 8D for later use.
  • Keep track of your learnings to enhance your problem-solving techniques.
  • Comparisons of the before and after
  • Celebration and acknowledgement of the group

How to Write an 8D report for your company when you have a product defect or a problem to solve?

An 8D report is a tool for managing a problem. It consists of eight columns and four rows:

  • The first row, called the title row, lists each column’s name.
  • Define the Problem
  • Determine Causes
  • Develop Solutions
  • Verify Solutions
  • Control Risks
  • Document Your Improvements and Lessons Learned (optional)
  • Closeout (optional).
  • 1a through 7a include action steps related to 1 through 7 above; 
  • 6b includes an optional section that can be used if it becomes necessary to document lessons learned from this process at some later time (e.g., after you implement Solution 3b).

8D Report Pros and Cons for manufacturers

8d report advantages:.

More awareness of the root cause (s)

It improves your quality control processes by identifying the potential causes of nonconformance at each stage of production and prioritizes corrective action steps based on their risk level, priority, impact, probability, etc., thus ensuring that you address the system issues first before they result in incurring costs due to rework/scrap or adverse customer response or regulatory intervention.

Enhanced quality control strategies and plans.

8D enables you to reduce lead times by identifying where bottlenecks are occurring within a process so that resource allocation can be adjusted accordingly in order to improve throughput while maintaining quality standards (i.e., having sufficient workers available at all stages). This can also help with preventing employee burnout by covering more shifts so there is less overtime required from employees who might otherwise be tired from working too many hours without breaks when there is high demand for their services during peak times (like Christmas shopping season).

Avoid future problems

The 8D report can help your manufacturing company avoid costly mistakes, as you can see exactly where problems may occur and take action to prevent them. 

Team-based approach

An 8D report gives you an opportunity to check if everything is running smoothly and confirm that everyone understands their tasks and responsibilities. With this information at hand, it’s easier to make improvements based on what works best or needs improvement in different areas of your business. In addition, it’s easy to access historical data on procedures and products.

Better communication flows

Finally, It also allows for better communication flows between teams responsible for different processes in the manufacturing process and reduces the amount of time spent investigating issues that aren’t really problems.

8D report Cons: 

Extensive training

There aren’t many cons to applying 8D problem solving techniques. The most important one is that it will require that people who take part in problem-solving activities obtain the right training and instructions on how 8D operates.

They will also need to comprehend other closely linked concepts related to 8D issue solving methodologies. Examples of these may be pareto charts , process maps, fishbone diagrams, and more.

Lack in flexibility

In addition, an 8D report is not a good tool when there are several problems at once or when an issue in the manufacturing process needs immediate attention. 

Dedicated budget

An 8D report also has requirements that smaller enterprises with fewer resources can find complicated and costly. For example: you need to have a dedicated budget to provide extensive training so your team has the right knowledge to do the job right. 

Technology to Assist in 8D Reporting for manufacturers

There are a number of software solutions available to help companies implement 8D programs and manage their Supplier Quality Management (SQM) efforts. 

Why should you digitize your 8D processes?

Automating the 8D report process will ensure that all problems are captured and reported consistently, with no one falling through the cracks.

It facilitates collaboration across teams and departments. All stakeholders will have access to information on the status of every problem as it progresses through its lifecycle, so they can respond quickly if an issue arises or make suggestions for how best to resolve it. This saves time and allows everyone involved in a particular issue to feel more connected with one another than they otherwise would be able to do without this kind of technology at their disposal.

8D Solutions

8D reporting is a powerful tool for monitoring progress and identifying issues in manufacturing. This can help you improve your processes, reduce cost, and increase profits. With the help of technology, you can easily keep track of your 8D reports. Here are some solutions to assist manufacturers with this process:

A program like SAP or Oracle ERP allows you to integrate 8D reporting into your system. This way, all information is in one place and updated automatically.

A no-code software tool like Azumuta allows you to integrate 8D reporting into your system. This way, all information is in one place and updated automatically. Easily capture data with your phone or tablet , while offline from the field at any time! Create an 8D report right away and distribute it to your stakeholders and coworkers and track corrective actions to team members through a single app.

With real-time data, companies can improve communication among team members, improve problem solving skills for individuals on the team (including managers), and develop new solutions for existing issues based on past experience with similar problems at other locations or companies.

Microsoft Office

If you don’t want to invest in new software at this time but still want an easy way to manage your project issues and progress, consider using an online database like Excel for managing risks, defects, quality assurance methods, etc. This will allow you to access information from anywhere with a laptop or mobile device. This way is rather tedious though and important information can be lost.

Digitize your 8D Processes

As you can see, there are many benefits to using a software for 8D reporting. While it may seem like a lot of work initially, once you get the hang of it, it will be easy to maintain and manage your 8D records. The most important thing is to start now! Make sure that your company gets started on an 8D reporting software today so that your team can begin documenting problems as soon as possible!

See how our platform can help streamline data collection, increase productivity, and increase quality assurance with a demo of Azumuta.

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