8D Problem Analysis

D0 Prepare to Launch 8D

As a response to a symptom, assess the necessity of the 8D process. If required, provide an emergency response        plan to protect the customer and initiate the 8D process.

D1 Establish the Team

Form a team that possesses process and/or product knowledge, and allocate sufficient time, authority, and        required techniques to solve the problem and implement corrective actions. The team must have a champion and a        leader to initiate team formation.

D2 Describe the Problem

Describe the internal/external customer problem by identifying "what went wrong" and detailing the        issue using quantifiable terms.
Clearly define, justify, and implement emergency containment actions to        isolate the problem from internal/external customers until permanent corrective actions are in place. Validate        the effectiveness of containment measures.

D3 Develop Interim Containment Actions 

Clearly assess, argue, and implement emergency containment actions to isolate issues from internal/external        customers until permanent solutions are in place. Validate the effectiveness of these containment measures.

D4 Define and Verify Root Cause and Escape Point

For the problem described, test each potential root cause, isolate and verify the root cause, and demonstrate        that at a specific point in the process, the root cause can be detected and its effects contained.

D5 Choose and Verify Permanent Corrective Actions (PCA)

Select the best permanent corrective action to eliminate the root cause. Choose the best PCA to contain the        effects of the root cause, and prove its success from both aspects when implementing the PCA, ensuring no        adverse side effects.

D6 Implement and Validate PCA

Plan and implement the selected PCA, discontinue interim containment actions, validate and monitor the long-term        effectiveness of the corrective action.

D7 Prevent Recurrence

Modify necessary systems including policies, practices, and processes to prevent recurrence of this and similar        issues. Provide necessary recommendations for systemic improvements and document lessons learned.

D8 Recognize Team and Individual Contributions

Complete the team's mission, sincerely acknowledge team and individual contributions, and celebrate success.

8D Problem Evaluation

To ensure consistency in application, the following checklist assists the team in achieving this goal:

Emergency Response Actions

1. Has the necessity of emergency response actions been assessed?

2. If an emergency response action is adopted, has it been validated?

3. If an emergency response action is adopted, has it been confirmed?

8D Application Criteria

4. Has the symptom been defined and quantified?

5. Have the parties experiencing or affected by the symptom been identified?

6. Do quantified measurements indicate a performance gap and/or does the priority (severity, urgency,                growth) of the symptom allow the start of the 8D process?

7. Is the cause of the problem unclear?

8. Have the necessary resources to fundamentally solve and prevent recurrence been submitted to management?

9. Is the complexity of the problem beyond the scope of an individual to solve?

Other

10. Is the new 8D a duplicate of an existing one?

General Tasks (as appropriate)

11. Are all changes documented (FMEA, control plans, process flow diagrams, etc.)?

12. Has measurability been reviewed?

13. Has the 8D report been updated?

14. Has the need for service actions been determined?

flowchart TD               A[InputKnow the symptoms] --> B[Define & Quantify Symptoms, Identify Customers and            Affected Parties]               B --> C{Is an EmergencyResponse Plan Needed?}               C -- No --> D[Collect Data, and Review]               C -- Yes --> E[Select Emergency Response Plan and Validate]               E --> F{Is the Emergency Response Validated?}               F -- No --> E               F -- Yes --> G[Develop Action Plan Implement, Confirm Emergency Response Plan]               G --> H{Is the Emergency Plan Confirmed?}               H -- No --> E               H -- Yes --> D               D --> I{Does the Recommended 8D Meet the Application Criteria?}               I -- No --> J{Do We Have Enough Information?}               I -- Yes --> K{Is the New 8D Overlapping with Existing Ones?}               J -- Yes --> L[Use Other Methods to Describe the Symptoms]               J -- No --> D               K -- Yes --> M[Provide Data to the 8D Team]               K -- No --> N[Start the 8D Process]               N --> O[Output 8D Process Begins]

Preparation

1. Have regular meeting times and locations been established?

2. Is the meeting room easily accessible?

3. Are appropriate team-building activities used to build relationships?

4. Is there sufficient preparation to help team members focus on team activities?

5. Is the purpose of each meeting clear?

6. Is the team notified of each meeting agenda?

Membership

7. Are personnel affected by the problem included in the team?

8. Does the 8D reflect the customer's perspective?

9. Does everyone have a reason to join the team? Have they been communicated with?

10. Does the team include all necessary inputs? Can team efficiency be maintained?

11. Do team members reflect the current status of the problem?

12. Do team members agree on team membership?

Product/Process Knowledge

13. Does the team require special skills and experience?

Process Flow and Working Relationships

14. Are the team's goals and membership clarified?

15. Does the team have sufficient authority to make decisions?

16. Has a communication plan for internal and external information exchange been established?

17. Do all team members understand and agree on the team's goals?

Roles

18. Has a champion been identified?

19. Has a team leader been identified?

20. Are roles and responsibilities of team members clear?

21. Is a facilitator needed to coach the process and manage team opinions?

General Tasks (as appropriate)

22. Are all changes recorded (FMEA, control plans, process flow, etc.)?

23. Has measurability been reviewed?

24. Has the 8D report been updated?

flowchart TD               B[8D Process – D1
Establish the Team]               B --> C[Appoint Champion]               C --> D[Assign Team Leader]               D --> E[Determine Needed
Skills & Knowledge]               E --> F[Select Team Members]               F --> G[Set Team Goals
and Member Roles]               G --> H[Establish Operating
Procedures]               H --> J[Team Member
Working Relationships
Team Formation]

Problem Statement

1. Has "what went wrong" been answered?

2. Has "why" been repeatedly asked to confirm understanding?

3. Has a specific problem statement (object and defect) been identified?

Problem Description

4. Has an Is/Is Not analysis been performed (what, where, when, how severe)?

5. Compared to past experience, has it been determined whether this issue occurred before?

6. Has the current process flow been identified?

7. Has any change in the original process been evaluated?

8. Have process details been checked to determine where the problem first appeared?

9. Has an engineering system design study been conducted? Has system transmission, function, and                interaction been understood?

10. Has the problem sample been considered/evaluated?

11. Have similar components or parts been reviewed for similar issues?

12. Has all necessary data for analysis been collected?

13. Has the effectiveness of emergency response actions on data been evaluated?

14. Has physical evidence of the problem been obtained?

15. Has a cause-and-effect diagram analysis been completed?

Problem Type

16. Has it been determined whether the problem describes a "change" or a "never                occurred" scenario?

Review of Problem Description

17. Does the problem description confirm the issue experienced by the customer and/or affected parties?

18. Has necessary management review been conducted?

19. Have financial reserves been considered?

20. Have ethical, social, and legal responsibilities related to the problem been considered?

General Tasks (as appropriate)

21. Have all changes been documented (FMEA, control plans, process flow)?

22. Have team members been reassessed?

23. Has measurability been reviewed?

24. Has the need for service actions been determined?

25. Has the 8D report been updated?

flowchart TD    A[Input to form a team] --> B[Data review]    B --> C[Can the symptom be broken down?]    C -->|Yes| D[For each symptom, refer back to 8D and apply the criteria]    C -->|No| E[State the symptom as an object and defect]    E --> F[Do we know the cause? Why repeated]    F -->|Yes| E    F -->|No| G[Document the problem statement]    G --> H[Begin problem description Yes/No]    H --> I[Identify the process flow]    I --> J[Identify additional data needed]    J --> K[Collect and analyze additional data]    K --> L[Does the problem description involve any changes?]    L -->|No| M[Does the problem description refer to a situation that has never occurred before?]    L -->|Yes| Q    M -->|No| B    M -->|Yes| N[Use the 8D process?]    N -->|No| O[Use other methods instead of experimental design, process improvement, and system innovation theory]    O --> P[Stop 8D]    N -->|Yes| Q[Use other methods to supplement 8D]    Q -->|Yes| R[Use other methods instead of experimental design, process improvement, and system innovation theory]    Q -->|No| S[Review the problem description with customers and all affected parties]    R --> S    S --> T[Output problem description]

Before Implementing ICA

1. Has the need for ICA been determined?

2. Have emergency containment actions been evaluated to select the best ICA?

3. Has consultation with the customer or champion been conducted to establish selection criteria for                interim actions?

4. Based on established criteria, does the ICA provide the best balance of benefit and risk?

5. Does the ICA 100% protect the customer from the problem?

6. Has the ICA been validated?

7. Is the ICA cost-effective and easy to implement?

Planning

8. Have appropriate departments participated in decision planning?

9. Have advanced quality planning tools (FMEA, control plans, work instructions) been considered?

10. Does the plan, including action steps, specify responsible persons, tasks, and timelines?

11. Has the customer's perspective been considered (if required)?

12. Has customer approval been obtained?

13. Has a validation method been established?

14. Have potential issues and temporary measures been considered?

15. Are implementation resources available and appropriate?

After Implementing ICA

16. Does validation data show the customer has been protected?

17. Has the ICA been evaluated for improvement?

General Tasks (as appropriate)

18. Have all changes been documented (FMEA, control plans, process flow)?

19. Have team members been reassessed?

20. Has measurability been reviewed?

21. Has the need for service actions been considered?

22. Has the 8D report been updated?

flowchart TD    A[Input problem description] --> B[Is interim containment action needed?]    B -->|No| C[Proceed to D4]    B -->|Yes| D[Assess emergency response actions]    D --> E[Identify the best interim containment actions and verify them]    E --> F[Has the interim containment action been verified?]    F -->|No| E    F -->|Yes| G[Develop action plans, implement, and confirm]    G --> H[Has the interim containment action been confirmed?]    H -->|No| E    H -->|Yes| I[Continue monitoring the effectiveness of interim containment actions]    I --> J[Output: Establish interim containment actions]

Root Cause

1. Has the actual information in the problem description (Is/Is Not) been updated?

2. Have differences between Is and Is Not been identified?

3. If the issue was caused by a change, has the change been identified?

4. Have assumptions made in D2 been tested?

5. Does the most probable cause explain the facts in D2?

6. Has the root cause been actively and/or passively verified?

7. Is the root cause analysis sufficient (we don't need to know why the root cause occurred)?

More Than One Root Cause

8. Do these causes explain all aspects of the problem description (e.g., expected performance level not                met)?

9. If feasible, has the team and leadership considered defining separate problem descriptions for each root                cause to initiate individual 8Ds?

10. If not feasible, has the team considered alternative problem-solving methods/tools (e.g., DOE, process                improvement, SIT) as: a) independent of 8D or b) a supplement to 8D?

Escape Point

11. Has the process flow been reviewed to identify the escape point linked to the root cause?

12. Has it been determined whether a control system exists to detect the issue?

13. If a control system exists, has the original design change been identified?

14. Has the control point closest to the root cause been identified?

15. Has the ability of the control system to detect the issue been verified?

16. Has the need to improve the control system been evaluated?

General Tasks (as appropriate)

17. Have all changes been documented (FMEA, control plans, flow)?

18. Have team members been reassessed?

19. Has measurability been reviewed?

20. Has the need for service actions been evaluated?

21. Has the 8D report been updated?

flowchart TD    A[Root Cause Flow Part 1]    B[Input interim containment actions] --> C[Review and update the problem description]    C --> D[Identify differences, changes, and improvement theories]    D --> E[Test if the problem targets the problem description]    E --> F[Does the principle explain all the data?]    F -->|No| C    F -->|Yes| G[Has the most likely cause been argued?]    G -->|No| C    G -->|Yes| H[Identify root causes]    H --> I[Are tH here multiple root causes?]    I -->|Yes| J[Root Cause Flow Part 2]    I -->|No| K[Output root causes]    K --> L[Root Cause Flow Part 3]
flowchart TD    A[Root Cause Process Part 2]    B[Does the root cause explain all facets described in the problem statement?] -->|Yes| C[Do we need to initiate an 8D for every single root cause identified?]    C -->|Yes| D[Move to D2]    B -->|No| E[Together with the champion, evaluate change-enabling approaches, e.g., Design of Experiments, process improvement, Systematic Inventive Thinking]    C -->|No| E    E --> F[ApEply the 8D process]    F -->|No| G[Employ the chosen change-enabling methods, e.g., DOE, process improvement, SIT, robust design]    G --> H[Suspend the 8D]    F -->|Yes| I[Supplement the 8D with change-enabling methods?]    I -->|Yes| J[Use change-enabling approaches to complement the 8D, e.g., DOE, process improvement, SIT, robust design]    I -->|No| K[Confirm the root cause]    J --> K    K --> L[Document and output the root cause]    L --> M[Missing-Process Section Part 3]
flowchart TD    A[Missing-Process Flow]    B[Review the process flow and identify control points for each root cause] --> C[Does a control system exist to detect the problem?]    C -->|Yes| D[Identify the control point closest to the root cause]    D --> E[Does a control system exist to detect this issue?]    E -->|Yes| F[Recognize this control point as the identified omission point]    F --> G[Output the validated omission point t]    C -->|No| H[Determine that the control system lacks capability]    E -->|No| H    H --> I[Recognize the need for a new or improved control system]    I --> J[Document and output the identified need for an improved control system]

Before Deciding on PCA

1. Have criteria for selecting PCA for root cause and escape point been established?

2. Has the champion agreed to the PCA criteria?

3. Does the team have experience to select the best PCA?

4. Have all available options been considered for PCA?

5. Have the characteristics and benefits of the best choice been protected?

6. Have risks associated with selection been managed?

7. Has the champion agreed to the selected PCA?

Validation

8. Does evidence of implementation show the problem has been solved at the root cause?

9. Has the method for confirming variation tolerance been defined based on the cause?

10. Has reasonable measurability for variables been established during validation?

11. Has the method for evaluating PCA been confirmed across the full range of product variation and                operating conditions?

After Deciding on PCA

12. Has risk assessment been conducted for the selected PCA?

13. If required, has consultation with the customer and affected parties been conducted?

14. Are interim containment actions effective before PCA implementation?

15. Have resources needed for PCA implementation been considered?

16. Have departments or other organizations involved in PCA planning and implementation been identified?

17. Has improvement of interim containment actions been considered before PCA implementation?

General Tasks (as appropriate)

18. Have all changes been documented (e.g., FMEA, control plans, flow charts)?

19. Have team members been reassessed?

20. Has measurability been reviewed?

21. Has the need for service actions been determined?

22. Has the 8D report been updated?

flowchart TD    A[Input the validated root cause] --> B[Root-cause process]    B --> C[Establish decision criteria]    C --> D[Identify possible actions]    D --> E[Select the best permanent action]    E --> F[Test and validate the permanent action]    F -->|Yes| G[Re-evaluate both temporary and permanent actions at the escape point]    F -->|No| C    G --> H[Does the champion approve the permanent action?]    H -->|Yes| I[Output the justified permanent action]    H -->|No| E    H -->|No| N    J[Input the justified escape point or the recognized need for an improved control system] --> K[Escape-point process]    K --> L[Establish decision criteria]    L --> M[Identify possible actions, including temporary containment measures]    M --> N[Select the best permanent action]    N --> O[Test and validate the permanent action]    O -->|Yes| P[Identify actions that can enhance the temporary containment]    O -->|No| L    P --> H    H -->|Yes| Q[Output the permanent action for the escape point]

Planning / Problem Prevention

1. Has support from other departments/organizations needed for PCA implementation been assessed?

2. Do representatives from these departments/organizations join the team to plan and implement PCA?

3. Have relevant customer or supplier needs been considered?

4. If required, has a plan to identify responsible parties for customers and/or suppliers been developed?

5. Has an action plan (clarifying responsibilities, establishing timelines, determining support needs) been                developed?

6. Have necessary resources for plan execution been identified?

7. Have potential errors at each step of the plan been considered, and what to do to prevent them?

8. Have appropriate temporary measures been prepared in case preventive measures fail?

9. Has the trigger (date and event) for temporary measures been determined?

10. Has the development of the plan been effectively monitored?

11. Does the plan include the date for discontinuing interim containment actions?

12. Has the plan been communicated to everyone who needs to know?

13. Has necessary training for plan execution been identified?

14. Has leadership approved the plan?

15. Has the measurability of PCA results (before and after) been determined?

Validation

16. Have interim containment actions been discontinued?

17. Can measurability confirm that undesired effects have been fully eliminated?

18. Has long-term monitoring been conducted?

19. Has the customer confirmed the effectiveness of PCA?

General Tasks (as appropriate)

20. Have all changes been documented (e.g., FMEA, control plans, flow charts)?

21. Have team members been reassessed?

22. Has measurability been reviewed?

23. Has the need for service actions been determined?

24. Has the 8D report been updated?

flowchart TD    A[Input the permanent action for the root cause] --> B[Root-cause process]    B --> C[Develop an action plan for the permanent action]    C --> D[Implement the action plan]    D --> E[Remove temporary actions and evaluate the permanent action at the escape point]    E --> F[Complete verification]    F --> G[Confirm with the customer—using symptoms and measurement methods—that the symptoms have been eliminated]    G --> H[Output the permanent action and its verification data]    I[Input the justified permanent action for the escape point] --> J[Escape-point process]    J --> K[Develop an action plan for the escape point]    K --> L[Implement the planned actions]    L --> M[Remove temporary containment measures]    M --> N[Complete verification]    N --> G

Problem History

1. Has how/where the problem entered the process been determined?

2. Has why the problem occurred and why it was not detected been confirmed?

3. Has it been determined whether confusion or lack of knowledge caused the occurrence and/or escape?

4. Have policies, methods, procedures, and/or systems that allowed the problem to occur and escape been                confirmed?

5. If process remedies are identified, have their implementation locations and compensations been                confirmed?

6. Have affected parties been identified?

Prevention

7. Have necessary policies, methods, procedures, and/or systems to prevent recurrence and escape been                determined?

8. Has evidence needed to identify process improvement methods (e.g., RAPID, focus improvement, redesign)                been evaluated?

9. Have individuals and/or organizations responsible for system, policy, method, and/or procedure design                improvements that led to root cause occurrence or escape been identified?

10. Has the best method to test these improvements been identified?

11. Have necessary standardized practices been identified?

12. Has a plan for adjusting preventive measures and standardizing management been documented?

13. Has leadership approved the identified preventive measures and plan?

14. Has a method for communicating changes to affected parties been identified?

15. Have new practices been standardized?

16. Have improved detection points to evaluate system improvements been identified?

Systemic Prevention Recommendations

17. Have management policies, systems, or procedures beyond the current leadership's scope for problem                occurrence or escape been confirmed?

18. Has responsibility for practices beyond the current leadership's scope been established?

19. Has current leadership agreed to the team's systemic prevention recommendations?

Lessons Learned

20. Have appropriate technical lessons been documented?

General Tasks (as appropriate)

21. Have all changes been documented (e.g., FMEA, control plans, flow charts)?

22. Have team members been reassessed?

23. Has measurability been reviewed?

24. Has the need for service actions been determined?

25. Has the 8D report been updated?

flowchart TD    A[Input the permanent actions and verification data] --> B[Review the problem’s historical records]    B --> C[Analyze how the problem occurred and how it escaped]    C --> D[Identify affected parties and the likelihood that similar issues could occur and escape]    D --> E[Identify system policies, practices, and processes that allowed the problem to occur and reach the customer]    E --> F[Analyze how similar issues could manifest]    F --> G[Identify and select preventive actions]    G --> H[Validate the preventive actions]    H --> I[Are the preventive actions effective?]    I -->|No| G    I -->|Yes| J[Develop the action plan for prevention]    J --> K[Does the champion approve the identified preventive action plan?]    K -->|No| G    K -->|Yes| L[Implement the preventive actions and verify their effectiveness]    L --> M[LSystem-level preventive recommendations for improvement]    M --> N[Current preventive recommendations for the process owner]    N --> O[Output the preventive actions for the current issue]    N --> P[Output the preventive actions for similar potential issues]    N --> Q[Output the system-level preventive recommendations]    O --> R[Transfer technical lessons into the lesson-learned system]    P --> R

8D Report

1. Has the 8D report been updated and published?

2. Has the current status of 8D been communicated to all who need to know, including the customer?

3. Has the 8D report and its attachments been retained?

Recognition Plan

4. Have all current and former team members been identified?

5. Have individual contributions of the team and its members been fully recognized?

6. Has recognition evaluation been conducted among champion-members, member-member, member-leader,                member-champion?

7. Have different methods of recognition communication been considered?

8. Have contributions of non-team members been considered for recognition?

Recognition Execution

9. Has public recognition of team members (e.g., company bulletin board) been considered?

10. Is recognition appropriate, focused, and timely?

11. Is the D8 trend positive? Have unexpected and negative trends been considered?

Lessons Learned

12. Has the team process been evaluated and lessons learned identified?

Closure

13. Has all unfinished work been completed?

14. Has each member had the opportunity to express gratitude to others?

15. Has each member made a final statement?

16. Has the team celebrated appropriately?

flowchart TD               B[Existing Problem Prevention Measures]               B --> C[Select Key Documents & Provide Preventive Actions
for Similar Issues]               D[Provide Preventive Actions for Similar Issues]               D --> C[Select Key Documents & Provide Preventive Actions
for Similar Issues]               F[System Prevention Recommendations]               F --> C[Select Key Documents & Provide Preventive Actions
for Similar Issues]               C --> G[Review Team Processes & Records, Team Lessons Learned]               G --> I[Recognize Whole Team’s Joint Effort in Problem Solving]               I --> J[Mutual Recognition of All Contributions During Problem Solving]               J --> K[Celebrate Team Task Completion]               K --> N[8D Complete,Dissolve Team]