8d problem solving workshop

The 8D (Disciplines) Problem Solving Process Workshop

Workshop Description

The 8D (Eight Disciplines) Problem Solving Process is a team-oriented and structured problem-solving methodology that is used to identify, correct, and eliminate recurring problems.

The 8D Problem Solving Process has become a standard in many industries as a problem-solving and improvement process, as well as an internal Corrective Action Request (CAR) Process and Supplier Corrective Action Request (SCAR) Process.

Workshop Benefits

The benefits of using the 8D Problem Solving Process to determine the root cause(s) of a problem or process performance gap and to establish permanent corrective and preventive actions are:

• 8D Problem Solving Teams play a key role in their organizations by being empowered to find root causes, implement corrective actions, prevent any recurrence, and recommend process improvements. These teams have the authority, responsibility, and accountability for solving problems in their work area,
• by using a standard process to solve problems and communicate lessons learned across the organization, teams can become more efficient and effective, which means that problems will be solved quickly, and
• by identifying the symptoms, implementing emergency response actions, and protecting the internal and external Customers from adverse effects of the problem, teams can resolve problems and further improve Customer Satisfaction.

Key Topics and Learning Points

The "8D Problem Solving Process" workshop is very interactive with examples and hands-on small group exercises. After the workshop, the participants will ...

• have a thorough understanding of the 8D Problem Solving Process
• be able to describe the purpose and objective of each phase of the 8D Problem Solving Process
• understand and be able to apply key problem solving tools in each phase of the 8D Problem Solving Process, including Pareto Chart, Histogram, Run Chart, 5 Whys, Is-Is Not Matrix, Process Flow Chart, Process Variables Map, Fishbone Diagram, Comparative Analysis, Scatter Plot, Box Plot, Process Failure Mode and Effects Analysis, Root Cause Theory Testing, Mistake-Proofing, and Process Control Plan
• be able to use assessing questions at the end of each phase of the 8D Problem Solving Process to ensure proper application of the process and integrated problem-solving tools

Workshop Requirements

Workshop Duration

This course is typically delivered as a two-day workshop. During the workshop, participants will apply the methodology and the integrated problem-solving tools in small teams using a case study and some actual problems and/or improvement opportunities identified by the organization.

Who Should Attend

Process owners, supervisors, team leaders, and employees throughout the organization involved in problem-solving and improvement activities. The optimum number of participants is 3 to 4 teams of 4 to 5 team members each.

Project Support

Hands-on implementation support, if needed to transfer the learning and exercises to existing manufacturing or service processes and problems, is of course available.

For more detail about this and other workshops please Contact Us . Visit our OpEx Academy for downloadable Training Materials , eLearning Modules , Online Courses , and Public Workshops offering.

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8D Problem Solving Training – On-Site and Online Workshops

Solve problems with 8D – effectively and permanently!

Course length:  16 hours (typical) training location:  on-site at your facility or online via zoom or teams..

Our most popular two-day 8D Problem Solving training course gives your people the skills and knowledge they need to solve problems efficiently with the industry-standard Global 8D model.

Our 8D course emphasizes practical use of problem-solving tools and includes technical concepts, classroom discussion, and  hands-on exercises.  Teams of participants will perform exercises that take them from the theoretical realm to the practical, in a team-oriented atmosphere.

The APS 8D Problem Solving training workshop our most popular on-site training course. We are proud to have conducted this course for for many thousands of attendees across the globe.

The content of our 8D training course can be customized to incorporate your company-specific forms, case studies, documentation, reports, etc. Call us to discuss the details.

New for 2024: A live online version of this training is available via Zoom, Teams, or other online platform. Call or email for more information.

8D Problem Solving Training Course Terminal Objective:

At the end of this workshop, the participants will be able to lead or participate as an effective team member a team-oriented problem solving effort, using a time-proven structured problem solving strategy (the 8D method) that gets results by: 

Solving problems by finding real root causes

Taking action that permanently removes the problem

Enabling objectives:

To achieve the terminal objective, the participants will learn to:

Describe the benefits of using a structured approach for solving problems.

Compare industry standard problem-solving models including 8D, PDCA, and DMAIC.

Implement the steps of the 8D process to solve a problem.

Identify which problem-solving tools are best used in conjunction with each step of the process.

Perform Pareto and IS/IS NOT analyses for problem identification and description.

Perform root cause analysis using structured brainstorming, 5 whys, cause and effect (fishbone or Ishikawa), run chart, and scatter diagram analyses.

Develop, implement, and verify permanent corrective actions using force field analysis, NGT, action matrix, and error proofing techniques.

Describe basic SPC principles including process capability (Cp, CpK).

Each participant will receive a copy of our 125-page Problem Solving Reference Guide and a flash drive loaded with helpful tools, electronic forms, checklists, templates, and case studies. These items can be used to build a robust 8D program and enhance future problem solving activities.

Find out why this 2-day 8D workshop is our most popular course  

8D Problem Solving Training – Typical Course Schedule (16-hr Course)

Day 1 – AM

• What is Problem Solving?
• Why use a structured process?
• D0 Prepare for the process
• D1 Use a team approach
• D2 Describe the problem
• D3 Implement and verify containment activity
• D4 Define root cause
• D5 Develop permanent corrective actions
• D6 Implement and verify corrective actions
• D7 Prevent recurrence
• D8 Congratulate your team
• DMAIC and Six Sigma
• Comparing DMAIC to 8D and PDCA
•  8D Documentation and examples
• Selecting the right tool for the job
• Getting started
• Problem selection
• Pareto charts
• Exercise: Create and interpret a Pareto chart
• Team selection and makeup
• Exercise: Form teams and perform initial data collection run for in-class case study

Day 1 – PM

• The importance of collecting and interpreting data
• Problem statements and operational definitions
• Flow charts
• Exercise: Use an IS/IS NOT worksheet to develop problem definition
• Containment strategies -Thinking outside the box
• Problems with containment
• Exercise: Identify possible containment strategies
•  Root cause analysis methodology
• Structured brainstorming techniques
• Cause and Effect (Fishbone) Diagrams
• Repeated Whys (5 Whys)
• Exercise: Use structured brainstorming methods, and a fishbone diagram to identify and classify possible root causes

Day 2 – AM

• Review of homework and case studies
• Cause of occurrence (technical)
• Cause of escape (non-detection)
•  Managerial root causes
• Systemic root causes
• Exercise: Design a simple experiment to isolate root cause
• Exercise: Create/analyze a run chart for root cause analysis
• Developing an Action Plan
• Error Proofing (Poka Yoke)
• Nominal Group Technique (NGT)
• Exercise: Use NGT to reach consensus on corrective actions – develop PCAs
• Putting the Action Plan into place
• Action Matrix
• Force Field Analysis

Day 2 – PM

• Histograms 
• Modified Scatter Diagrams
• Exercise: Create/analyze a scatter diagram
• Identifying recurrence issues
• Leveraging your success for maximum ROI
• Concepts of SPC
•  Process Capability (Cp and CpK)
•  D8 Congratulate Your Team
• 8D Auditing
• Summary and Wrap-up

All APS courses are conducted on-site at our clients’ facilities. The course content may be customized to fit your specific needs. For a free quote or for more information on this course, email us at  [email protected]  or call us at 610-987-4050.

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8D Problem Solving Training Workshop

8D Problem Solving Training

8D Problem Solving Training workshop, Learn 8D (Eight Disciplines of Problem Solving) process to solve complex problems.

The eight discipline (8D) problem-solving training covers the eight disciplines (8D) model used for problem solving. 8D methodology is designed for quality engineers or other professionals to identify, correct, and eliminate recurring problems, making it useful in product and process improvement.

This unique course provides an overview of the 8D process, gives guidance on tools for finding root causes, shows 8D in action in eight case studies, and gives five unsolved problems for participants to apply 8D themselves for practice.

Program Agenda

OVERVIEW OF 8D APPROACH

• Select an appropriate team
• Formulate the problem definition
• Activate interim containment
• Find root cause(s)
• Select and verify correction(s)
• Implement and validate corrective action(s)
• Take preventive steps
• Congratulate the team

HOW TO USE THE 8D APPROACH

• D0: Plan – Plan for solving the problem and determine the prerequisites.
• D1: Use a team – Select and establish a team of people with product/process knowledge.
• D2: Define and describe the problem – Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many (5W2H) for the problem.
• D3: Develop interim containment plan; implement and verify interim actions – Define and implement containment actions to isolate the problem from any customer.
• D4: Determine, identify, and verify root causes and escape points – Identify all applicable causes that could explain why the problem occurred. Also identify why the problem was not noticed at the time it occurred. All causes shall be verified or proved, not determined by fuzzy brainstorming. One can use 5 Whys and cause and effect diagrams to map causes against the effect or problem identified.
• D5: Choose and verify permanent corrections (PCs) for problem/nonconformity – Through preproduction programs, quantitatively confirm that the selected correction will resolve the problem for the customer.
• D6: Implement and validate corrective actions – Define and implement the best corrective actions (CA).
• D7: Take preventive measures – Modify the management systems, operation systems, practices, and procedures to prevent recurrence of this and all similar problems.
• D8: Congratulate your team – Recognize the collective efforts of the team. The team needs to be formally thanked by the organization.

8D Workshop (Custom Project)

• 0D – Planning
• 1D – Establishing the team
• 2D – Problem description
• 3D – Containment action
• 4D – Root Cause
• 5D – Corrective action
• 6D – Validate corrective action
• 7D – Prevent recurrence
• 8D – Verify and congratulate Team

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8D Problem Solving

This workshop provides a detailed understanding of the 8D problem solving process. Working through the structured steps, learners use practical examples to illustrate the key stages of problem definition, cause and effect analysis, 5 Why, containment actions, root cause identification, corrective action, implementation, and preventing recurrence.

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8 Disiplines of Problem Solving (8D)

The 8D Problem Solving methodology is commonly known as “Eight Disciplines of Problem Solving” or simply “8D.” It is a structured, team-based approach to identifying, analyzing, and resolving problems, particularly in the areas of product quality and process efficiency.

What is 8D Problem Solving?

Related posts, 8d problem-solving: common mistakes to avoid, the evolution of 8d problem-solving: from basics to excellence, 8d: tools and techniques, 8d problem solving: the key to effective root cause analysis, 8d problem solving check list, helpful 8d problem solving resources, 8d report template, 8d problem solving guide, 8d knowledge test.

Assess your’s or your teams understanding of 8D Provlem Solving.

When to use 8D Problem Solving

One of the key advantages of using 8D is its focus on data-driven decision-making, which aligns well with Lean Six Sigma principles. It’s a methodical approach that demands the collection of data at every stage, right from defining the problem to verifying the effectiveness of corrective actions.

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Featured Reads

• Project management |
• What is 8D? A template for efficient pr ...

What is 8D? A template for efficient problem-solving

How you respond when problems arise is one of the most defining qualities of a manager. Luckily, there are tools you can use to master problem-solving. The 8D method of problem-solving combines teamwork and basic statistics to help you reach a logical solution and prevent new issues from arising.

You’ve spent months overseeing the development of your company's newest project. From initiation, planning, and execution, you’re confident this may be your best work yet.

Until the feedback starts rolling in.

There’s no sugar-coating it—things don’t always go as planned. But production or process issues are hardly a signal to throw in the towel. Instead, focus on honing your problem-solving skills to find a solution that keeps it from happening again. 

The 8D method of problem solving emphasizes the importance of teamwork to not only solve your process woes but prevent new ones from occurring. In this guide, we’ll break down what 8D is, how to use this methodology, and the benefits it can give to you and your team. Plus, get an 8D template to make solving your issue easier. 

What is 8D?

The eight disciplines (8D) method is a problem-solving approach that identifies, corrects, and eliminates recurring problems. By determining the root causes of a problem, managers can use this method to establish a permanent corrective action and prevent recurring issues. 

How do you use the 8D method?

The 8D method is a proven strategy for avoiding long-term damage from recurring problems. If you’re noticing issues in your workflow or processes, then it’s a good time to give this problem-solving method a try. 

To complete an 8D analysis, follow “the eight disciplines” to construct a statistical analysis of the problem and determine the best solution.

The eight disciplines of problem-solving

8D stands for the eight disciplines you will use to establish an 8D report. As you may notice, this outline starts with zero, which makes nine total disciplines. The “zero stage” was developed later as an initial planning stage. 

To illustrate these steps, imagine your organization experienced a decline in team innovation and productivity this past year. Your stakeholders have noticed and want to see changes implemented within the next six months. Below, we’ll use the 8D process to uncover a morale-boosting solution.

D0: Prepare and plan

Before starting the problem-solving process, evaluate the problem you want to solve. Understanding the background of the problem will help you identify the root cause in later steps. 

Collect information about how the problem has affected a process or product and what the most severe consequences may be. Planning can include:

Gathering data

Determining the prerequisites for solving the problem

Collecting feedback from others involved

If we look back at our example, you may want to figure out whether this decline in morale is organization-wide or only applies to a few departments. Consider interviewing a few employees from different departments and levels of management to gain some perspective. Next, determine what knowledge and skills you will need to solve this lapse in productivity. 

D1: Form your team

Create a cross-functional team made up of people who have knowledge of the various products and workflows involved. These team members should have the skills needed to solve the problem and put corrective actions in place. 

Steps in this discipline may include:

Appointing a team leader

Developing and implementing team guidelines

Determining team goals and priorities

Assigning individual roles

Arranging team-building activities

From our example, a solid team would consist of people with first-hand experience with the issues—like representatives from all departments and key people close to workshop-level work. You may also want to pull someone in from your HR department to help design and implement a solution. Most importantly, make sure the people you choose want to be involved and contribute to the solution.

D2: Identify the problem

You may have a good understanding of your problem by now, but this phase aims to break it down into clear and quantifiable terms by identifying the five W’s a and two H’s (5W2H):

Who first reported the problem?

What is the problem about?

When did it occur and how often?

Where did it occur (relating to the sector, supplier, machine, or production line involved)?

Why is solving the problem important?

How was the problem first detected?

How many parts/units/customers are affected?

Use your team’s insights to answer these questions. From our example, your team may conclude that: 

Employees feel overwhelmed with their current workload. 

There is no real structure or opportunity to share new ideas.

Managers have had no training for meetings or innovation settings.

Disgruntled employees know they can achieve more—and want to achieve more—even if they seem disengaged.

Once you answer these questions, record an official problem statement to describe the issue. If possible, include photos, videos, and diagrams to ensure all parties have a clear understanding of the problem. It may also help to create a flowchart of the process that includes various steps related to the problem description.

D3: Develop an interim containment plan

Much like we can expect speedy first aid after an accident, your team should take immediate actions to ensure you contain the problem—especially if the problem is related to customer safety. 

An interim containment plan will provide a temporary solution to isolate the problem from customers and clients while your team works to develop a permanent corrective action. This band-aid will help keep your customers informed and safe—and your reputation intact.

Because your findings revealed workers were overworked and managers lacked training, your team suggests scheduling a few mandatory training sessions for leaders of each department covering time and stress management and combating burnout . You may also want to have a presentation outlining the topics of this training to get key managers and stakeholders interested and primed for positive upcoming changes. 

D4: Verify root causes and escape points

Refer back to your findings and consult with your team about how the problem may have occurred. The root cause analysis involves mapping each potential root cause against the problem statement and its related test data. Make sure to test all potential causes—fuzzy brainstorming and sloppy analyses may cause you to overlook vital information. 

In our example, focus on the “why” portion of the 5W2H. You and your team identify six root causes:

Managers have never had any training

There is a lack of trust and psychological safety

Employees don’t understand the objectives and goals

Communication is poor

Time management is poor

Employees lack confidence

In addition to identifying the root causes, try to pinpoint where you first detected the problem in the process, and why it went unnoticed. This is called the escape point, and there may be more than one. 

D5: Choose permanent corrective actions

Work with your team to determine the most likely solution to remove the root cause of the problem and address the issues with the escape points. Quantitatively confirm that the selected permanent corrective action(s) (PCA) will resolve the problem for the customer. 

Steps to choosing a PCA may include:

Determining if you require further expertise

Ensuring the 5W2Hs are defined correctly

Carrying out a decision analysis and risk assessment

Considering alternative measures

Collecting evidence to prove the PCA will be effective

Your team decides to roll out the training used in the interim plan to all employees, with monthly company-wide workshops on improving well-being. You also plan to implement meetings, innovation sessions, and team-coaching training for managers. Lastly, you suggest adopting software to improve communication and collaboration. 

D6: Implement your corrective actions

Once all parties have agreed on a solution, the next step is to create an action plan to remove the root causes and escape points. Once the solution is in effect, you can remove your interim containment actions.

After seeing success with the training in the interim phase, your stakeholders approve all of your team’s proposed PCAs. Your representative from HR also plans to implement periodic employee wellness checks to track employee morale .

To ensure your corrective action was a success, monitor the results, customer, or employee feedback over a long period of time and take note of any negative effects. Setting up “controls” like employee wellness checks will help you validate whether your solution is working or more needs to be done. 

D7: Take preventive measures

One of the main benefits of using the 8D method is the improved ability to identify necessary systematic changes to prevent future issues from occurring. Look for ways to improve your management systems, operating methods, and procedures to not only eliminate your current problem, but stop similar problems from developing later on.

Based on our example, the training your team suggested is now adopted in the new manager onboarding curriculum. Every manager now has a “meeting system” that all meetings must be guided by, and workloads and projects are managed as a team within your new collaboration software . Innovation is improving, and morale is at an all-time high!

D8: Celebrate with your team

The 8D method of problem-solving is impossible to accomplish without dedicated team members and first-class collaboration. Once notes, lessons, research, and test data are documented and saved, congratulate your teammates on a job well done! Make an effort to recognize each individual for their contribution to uncovering a successful solution.

8D report template and example

Check out our 8D report template below to help you record your findings as you navigate through the eight disciplines of problem solving. This is a formal report that can be used as a means of communication within companies, which makes for transparent problem-solving that you can apply to the entire production or process chain.

Benefits of using the 8D method

The 8D method is one of the most popular problem-solving strategies for good reason. Its strength lies in teamwork and fact-based analyses to create a culture of continuous improvement —making it one of the most effective tools for quality managers. The benefits of using the 8D method include: 

Improved team-oriented problem-solving skills rather than relying on an individual to provide a solution

Increased familiarity with a problem-solving structure

A better understanding of how to use basic statistical tools for problem-solving

Open and honest communication in problem-solving discussions

Prevent future problems from occurring by identifying system weaknesses and solutions

Improved effectiveness and efficiency at problem-solving

Better collaboration = better problem solving

No matter how good a manager you are, production and process issues are inevitable. It’s how you solve them that separates the good from the great. The 8D method of problem solving allows you to not only solve the problem at hand but improve team collaboration, improve processes, and prevent future issues from arising. 

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A Comprehensive Guide To 8D Problem Solving

Effective problem-solving is crucial for organizations to thrive.

The 8D problem-solving method is a systematic approach that helps teams identify, analyze, and resolve complex problems.

This guide will provide an overview of the 8D problem-solving method within corporate learning and problem-solving, including its definition, best practices, features, pros and cons, benefits, and examples.

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The 8D problem-solving method, also known as the Eight Disciplines , is a structured approach used to address and resolve problems in a systematic manner.

It was originally developed by the Ford Motor Company and has since been widely adopted across various industries.

The method consists of eight steps that guide teams through the problem-solving process, ensuring a thorough analysis and effective resolution.

Best Practices

To effectively implement the 8D problem-solving method within corporate learning and problem-solving, consider the following best practices:

• Cross-functional teams : Form diverse teams with representatives from different departments or areas of expertise. This ensures a comprehensive understanding of the problem and encourages collaboration.
• Clear problem statement : Begin by clearly defining the problem and its impact on the organization. This helps focus the team’s efforts and ensures everyone is aligned on the issue at hand.
• Data-driven analysis : Gather relevant data and facts to analyze the problem objectively. Utilize tools such as root cause analysis, fishbone diagrams, and Pareto charts to identify the underlying causes.
• Systematic approach : Follow the eight disciplines of the 8D problem-solving method sequentially. Each step builds upon the previous one, ensuring a thorough and structured approach to problem-solving.
• Effective communication : Maintain open and transparent communication within the team and with stakeholders. Regularly update all involved parties on the progress, findings, and proposed solutions.
• Continuous improvement : Encourage a culture of continuous improvement and the promotion of employee training courses by documenting lessons learned and implementing preventive measures to avoid similar problems in the future.

The 8D problem-solving method encompasses the following key features:

• Structured approach : The method provides a step-by-step framework that guides teams through the problem-solving process, ensuring a systematic and comprehensive analysis.
• Team collaboration : The method encourages cross-functional collaboration, bringing together individuals with diverse perspectives and expertise to collectively solve the problem.
• Root cause analysis : The 8D method emphasizes identifying and addressing the root causes of the problem rather than merely treating the symptoms. This helps prevent recurrence of the issue.
• Data-driven decision-making : The method emphasizes the use of data and facts to drive the problem-solving process, ensuring objective analysis and informed decision-making.

Pros and Cons

Pros of using the 8D problem-solving method within corporate learning and problem-solving include:

• Provides a structured and systematic approach to problem-solving.
• Encourages collaboration and cross-functional teamwork.
• Focuses on identifying and addressing root causes.
• Promotes data-driven decision-making.
• Facilitates continuous improvement and learning.

Cons of using the 8D problem-solving method include:

• Requires time and resources to implement effectively.
• May not be suitable for simple or straightforward problems.
• Relies on accurate data and information, which may not always be readily available.

Implementing the 8D problem-solving method within corporate learning and problem-solving can yield several benefits, including:

• Improved problem-solving capabilities: The method equips teams with a structured approach and tools to effectively analyze and resolve complex problems.
• Enhanced collaboration: By involving cross-functional teams, the method promotes collaboration and knowledge sharing, leading to innovative solutions.
• Preventive measures: The emphasis on root cause analysis helps identify and address underlying issues, reducing the likelihood of problem recurrence.
• Data-driven decision-making: The method encourages the use of data and facts, enabling informed decision-making and reducing reliance on subjective opinions.

Let’s consider an example to illustrate the application of the 8D problem-solving method:

Problem: A manufacturing company is experiencing a high defect rate in one of its product lines, resulting in customer complaints and increased costs.

• D1: Form a team : Assemble a cross-functional team consisting of representatives from production, quality control, and engineering.
• D2: Define the problem : Clearly define the problem, including the specific product line, defect types, and their impact on customers and costs.
• D3: Containment actions : Implement immediate actions to contain the problem, such as segregating defective products and halting production.
• D4: Root cause analysis : Use tools like fishbone diagrams and Pareto charts to identify potential root causes. Analyze data and conduct investigations to narrow down the causes.
• D5: Corrective actions : Develop and implement corrective actions to address the identified root causes. This may involve process changes, equipment upgrades, or training programs.
• D6: Preventive actions : Implement preventive measures to avoid similar problems in the future. This may include updating standard operating procedures, conducting regular audits, or enhancing training programs.
• D7: Verify effectiveness : Monitor and measure the effectiveness of the implemented corrective and preventive actions. Use data and feedback to validate the improvements.
• D8: Standardize and share : Document the entire problem-solving process, including the findings, actions taken, and lessons learned. Share this knowledge across the organization to facilitate learning and continuous improvement.

By following the 8D problem-solving method, the manufacturing company can systematically address the high defect rate, reduce customer complaints, and improve overall product quality.

The 8D problem-solving method is a valuable tool within corporate learning and problem-solving.

By providing a structured approach, promoting collaboration, and emphasizing root cause analysis, it enables organizations to effectively address complex problems and drive continuous improvement.

By implementing the best practices outlined in this guide, organizations can harness the benefits of the 8D method and enhance their problem-solving capabilities.

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RCA 8D Training – Virtual Workshop – Fall 2023

Quality-One is pleased to present Root Cause Analysis RCA 8D Training Workshop. This deep-dive course teaches various techniques to perform a more thorough Root Cause Analysis .  Exercises combine instructor-led training and team activities to engage all attendees in a learn-do approach.  Users of 8D , 5 Why and Six Sigma will gain a concise understanding and the skills required to make Problem Solving Processes more effective and efficient.   Click Here for the RCA Training Course Outline!

Quality-One is hosting this event March 2023 in a “Virtual Format Online”. Upon successful completion of this course, attendees will receive Certification from Q-1.

The registration fee of $995 per workshop participant will cover the complete two-session course, materials and certification.

To register, please call (248) 280-4800 or email  [email protected]

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Corrective Action/Root Cause Analysis Workshop – Employing the 8D Problem Solving Methodology – Virtual September 2024

Course summary.

This course is designed for anyone interested in improving their problem-solving skills and corrective action processes utilizing the 8D Problem Solving method.

$ 977.00

September 05, 2024 - September 06, 2024

Event details, description, who should attend, learning objectives, course outline, prerequisites, instructors.

16 hours Combination lecture and classroom exercises Available at QSG’s training facilities, on-site at your organization, and virtually

Start date: September 05, 2024

End date: September 06, 2024

Start time: 08:30 a.m. EDT

End time: 04:30 p.m. EDT

Venue: Virtual on Zoom

Directions: Training will occur on Zoom. You will be provided with a unique link per registrant. Please plan to login 10 minutes prior to the session start time.

When some people hear about “eight disciplines” for solving problems, they immediately think that it must be a complex or convoluted methodology.  Actually, the 8D Problem Solving process is really not all that complicated.  In fact, a number of common problem-solving models are quite similar to this team-based, data-driven approach to solving problems.

8D is a highly structured and effective scientific approach to solving chronic or recurring problems. It uses team synergy and provides excellent guidelines for identifying the root cause of the problem, implementing containment actions, and then developing and implementing lasting corrective and preventive action.

The 8D Problem Solving methodology is deployed to solve critical, major, chronic and recurring problems. It is most effective in addressing complex problems that exceed the ability of one person to resolve them. In this highly interactive workshop, you will learn how to solve future problems by applying a structured methodology that will yield faster and more effective solutions. The program provides opportunities to practice and apply the technique to case studies and participants’ on-job problems.

In this course, participants will learn how to follow the 8D process steps while working in a cross functional team. They will also apply various problem solving tools to identify and verify a root cause and eliminate it through permanent corrective action, followed by additional action to prevent reoccurrence of the root cause(s). Participants can expect team activities and relevant exercises in a workshop format. All activities will include industry-specific examples and terminology.

This course is designed for managers, engineers, scientists, and other professionals involved in their organizations’ process improvement efforts, as well as anyone interested in improving their problem-solving skills and corrective action processes.  This workshop is most beneficial when a team from your organization attends together.

Upon completion of training, each participant will have the analytical and procedural information needed to understand, describe, and participate in the 8D problem solving process as a team leader, team member, or facilitator.

Welcome and Participant Introductions List attendees’ personal concerns and objectives for the training

Introduction to Eight Discipline (8D) Problem Solving What is a problem? Difficulties and pitfalls in solving problems What is an 8D? Getting started on an 8D Problem awareness/triggers for the 8D

An Overview: 8D Steps and Objectives for Each Step Knowing what’s to be accomplished at each step

8D Steps 0 and 1 Problem assessment Preliminary fact gathering Forming the project team Roles and responsibilities: Management 8D champion Team leader Team members Facilitator

8D Step 2: Describe the Problem The key to effective 8D investigations Do Step 2 well and 8D flows smoothly “A problem well-defined is a problem half-solved.” (B. Fuller)

Kepner-Tregoe/IS/IS NOT/Systematic Root Cause Analysis Six steps to Systematic Root Cause Analysis Naming the problem Describing the problem (problem specification) Problem specification dimensions and questions IS/IS NOT problem description Deriving distinctions and changes from the IS/IS NOT Information Break

8D Step 3: Containment Types of containment activities Monitoring and verifying containment effectiveness Containment does not solve the problem!

Step 4: Identify Root Cause(s) “Occurrence, escape and systemic” root causes Tools employed at Step 4 Process flow/process maps Brainstorming Cause-and-effect (CE) analysis CNX (control, noise, experiment) Standard Operating Procedure (SOP) Test theories of causes against problem description (Step 2 above)

Workshop to Apply Step 4 Tools

Step 5: Develop and Verify Solution Considerations and objective Developing and selecting solutions Verifying that the solution is effective Error-proofing Step 5 Checklist

Step 6: Implement and Validate Corrective Action Objective and highlights of Step 6 Developing an action plan for implementation Issues to be addressed in plans for implementation and verification Be sure to update FMEA, control plan and other documents to reflect Changes and improvements introduced at Step 6

Examples of 8D Steps 5 and 6

Step 7: Prevent Problem Reoccurrence Considerations: Extend the fix; extend the cause, stair-step the cause Look at the problem and solution systemically “Drill deep” to address systemic root cause(s) Change/update management systems Emphasis shifts to prevention

Step 8: Recognize the Team Recognize and publicize the team’s accomplishments Don’t keep your candle under a bushel! Make sure customers (internal and external) know about the successful application of the 8D methodology.

Upcoming Events

Failure mode and effects analysis (fmea) based on aiag-vda harmonized edition – virtual october 2024, basic problem solving – virtual september 2024, measurement system analysis (msa) for gauge r&r – virtual october 2024, design of experiments (doe) basic – on-site september 2024, design for manufacturing and assembly (dfm&a) – on-site october 2024, blueprint reading – on-site october 15-16, 2024, gd&t part 1 (basic) – on-site october 29-31, 2024, leadership effectiveness training (l.e.t.) for process improvement – on-site, september 16-17, 2024, customer reviews, john gaumond.

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Paul was definitely very knowledgeable, shared much of his experiences and was very personable. He was able to take a topic that could be very dry and made it interesting. The overall thoughts were that both classes were valuable – especially to those with only several years in the industry.

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Thank you for the Holiday cheers! We look forward to working with QSG in 2018. We’ve accomplished a lot together as partners and our Training Program has been a great success thanks to you and QSG. Autoliv’s employees are very grateful to QSG for the opportunities to learn new skills and Autoliv appreciates our employees using these new skills to continually improve our Organization.

The training workshops have been very well received and we are very happy with all that have been completed. The upcoming 5S training is full and we already have others interested so we will be looking to add a class. I am also pushing for additional training with all the training events in all areas of our business.

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CTP-CTP7976 - 8D Problem Solving (LE)

Course description, course outline.

1.  The Problem Solving Process

     a.  Outline of the 8 Discipline (8D) Process

     b.  Phase D0 - Initiating the Process

     c.  Phase D1 - Establishing the Team

     d.  Phase D2 - Describing the Problem

     e.  Phase D3 - Interim Containment Action

     f.   Phase D4 - Root Cause Analysis

     g.  Phase D5 and D6 - Selecting, Implementing, and Validating Corrective Action

     h.  Phase D7 - Preventative Action

     i.  Phase D8 - Congratulating the Team and Capturing Lessons Learned

Learner Outcomes

Upon successful completion of this course, participants will be able to:

1.  Understand and explain the elements in the 8D process.

2.  Apply the 8D methodology in practice exercises.

Method of instruction:  lecture and class exercises

Method of evaluation:  class participation and practice exercises

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