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8D Training Material

Solving Problems Now Made Easy – An Approach in an


Automobile Industry To Solve Problems Effectively

© | VDiversify.Inc | All Rights Reserved 1


Introduction / Overview

© | VDiversify.Inc | All Rights Reserved 2


Problem Solving Inhibitors

1 Problem Described • Problem Description was not clear enough or thorough enough to
Incorrectly: Focus the Team on Solving the Correct Issue
2 Problem-Solving
• To move quickly, Steps in the Problem-Solving Process are skipped
Effort Rushed:
3 Poor Team • Team Members do not participate effectively, so Team failed to
Participation: consider all the Causes (Lack of Cross-Functional Expertise)
4 No Logical Process:
• A Disciplined System to Prioritize, Analyze, and Review Data /
Information was not used
5 Lack of Technical • Statistical and Problem-Solving methods are not known by Team
Skills: Members
6 Management • Due to Lack of Knowledge of the Problem-Solving Process, Management
Impatience: demands to know exactly when a Problem will be Solved. This Pressure
Causes the Team to make an inadequate Analysis
7 Misidentified Root • A Potential Cause is quickly identified as a Root Cause, concluding
Cause: the Problem Investigation. However, the Problem returns since the
true Root Cause was Not Eliminated
8 Permanent • Although a Root Cause may be identified, Action is taken to fully
Corrective Actions implement the Permanent Corrective Actions. These Actions often
Not Implemented: require Management to Approve Costs and implement
© | VDiversify.Inc | All Rights Reserved 3
Types of Problem Solving

1 Reactive (8D, 10 Steps): Activities undertaken to respond to a specific Customer Complaint


(e.g.: Product Return) where a Corrective Action response is requested
2 Pro-Active (A3): Activities undertaken to address Performance Gaps identified by Data Analysis
(e.g.: Key Metrics)
3 Day-To-Day • Although “Just Do It” Activities (e.g.: Equipment Breakdown)
(“Quick Kills”) - PDCA: • No Team required

What is meant by 8D?

It is short for “Eight Disciplines,” which are Eight distinct Steps of a Systematic
Process for Solving Problems

Where Does It Come From?

There are several Problem-Solving approaches available, such as Kepner-Tregoe, the


Deming Cycle, A3 and PDCA, etc. Ford Motor Company combined many of the
successful elements from these into their Team Oriented Problem Solving (TOPS)
Workshop, which this approach is based on.

Corrective Action reporting from many diverse Customers requires applying the 8D Approach

© | VDiversify.Inc | All Rights Reserved 4


8D Problem Solving Methodology
Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 5


Applying 8D Methodology

1 Predicated on Team Approach

2 Use for a Cause - Unknown Situation (all Significant Problems, Not just Customer Returns)

3 Fact-based, Data-Driven Decision Making. “If You Can’t Prove It, Don’t Say It !”

4 Eliminate the Problem, Not the Symptom

5 Requires Action Planning and Documentation for each Step of the Process

6 Focus On effectively using the Process, NOT on writing the report

7 Keep an Open Mind Facts / Data will guide us

© | VDiversify.Inc | All Rights Reserved 6


8D vs Continuous Improvement

8D Process Continuous Improvement Process

• Use an 8D Process where there is a Deviation • Use a Continuous Improvement Process where the
between Actual Performance and Expected Actual Performance meets the Expected
Performance Performance, but a Higher Level of Performance is
• 8D is a Reactive Process desired
• Continuous Improvement is a Proactive Process
Step 1: Form A Team
Use A Team Approach
Explore !
Step 2: Describe The Problem 1. Initiate Project Improvement
2. Identify Customer Needs
Step 3: Implement Containment Actions
3. Understand Current Process
Step 4: Identify Root Cause Actions
4. Characterize Process with Data
5. Design New Process
Step 5: Develop & Verify Solution Innovate
6. Pilot & Verify New Process
Step 6: Implement & Validate Corrective Actions 7. Standardize New System
Step 7: Prevent Problem Recurrence Pursue
Continuous
Step 8: Congratulate The Team 8. Recognize Team Improvement
The use of Six Sigma Methods involves Continuous Improvement and Innovation via
Specific Tools used to: Define, Measure, Analyze, Improve and Control (DMAIC)
© | VDiversify.Inc | All Rights Reserved 7
Advantages of 8D Methodology

Systematic, Yet Flexible


Provides a Structure
Superior To Usual Methods

Efficient Interdepartmental Communication


Common Approach Widespread Familiarity
Effective Management Evaluation & Control

More Skills & Creativity


Why Use Team Work
Buy-in Eases Implementation
8D?
Good Data Indisputable
Fact Based
Eliminates Personnel Biases

Tied To Deming Philosophy


Quality Methods Powerful & Commonly Available Statistical Tool
8D Provides Framework For Application of Methods

Standard Format For Reporting All Actions


Documentation
Later Reference Provides Insight To Problem Solutions

© | VDiversify.Inc | All Rights Reserved 8


Step 1 Initiate The Project Team

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 9


Objective

Establish a Team of People with Product and Process Knowledge, Skill in the various Technical
Disciplines or SME’s, and allocate Time and Authority to implement the Actions to solve a Problem

• Employee involvement / Participative


Supporting Concepts &
• Team Leadership Skills
Methods
• Meeting Facilitation Skills

Team Composition

Members Team Size


Good Team Members are Personnel’s Who are: 3 to 7 Members is Optimum. With fewer than 3
Members, Creativity and Skills are limited and
1 Willing To Contribute with more than 7 the Team is too Large for
Effective Team Dynamics
2 Capable of Diagnosing Problems
3 Trainable in the Use of Improvement Methods Experts with Specific Skills can be rotated in and
out of the Team as their Skills are needed
4 Team Players, rather than Individual Participants

© | VDiversify.Inc | All Rights Reserved 10


Team Formation

Multi-Discipline Project Teams

Project Team
Accounting
Product & Manufacturing
Supplier Engineering

External Customer Marketing


Purchasing Human Resources
Quality Assurance Material Control

Production

• Identify the expected time commitment from team members and ensure availability
> Management support needed

• Goals must be clearly specified, quantifiable, and supported by all.

© | VDiversify.Inc | All Rights Reserved 11


Why A Team Approach?

Advantages of Teams
More Talent

Doing Business today is tougher More Experience


Skills
than ever: More Knowledge
More Technical Competence
• More Demands
• Complex Problems Cross Departmental Lines
Increased Productivity
• Need to avoid Wasted Communication (More Theories & Ideas)
Money, Time and Effort
Increased Dignity & Morale

A Team of Individuals can Consensus Decision-Making


combine their Skills / Knowledge Participation Buy-in To Changes
to solve these Problems that are
Job Enrichment
beyond the capability of any one
person to solve alone Better Solutions

Solutions More Likely To


Effectiveness Be Accepted

Responsibility To Complete
Slated Mission

© | VDiversify.Inc | All Rights Reserved 12


Pitfalls To Avoid

• No Leader Empowered to implement Ideas

• No Champion assigned or available to assist the Team in time of need

• Personality Conflicts, Domination by one member, or Negative Attitudes (Why am I here?)

• Excessive Management Expectations, not enough time

• Insufficient Problem Solving Skills by Members

• Undefined Progress – No sense of urgency, No Goals

• Lack of Data / Facts, not shared by all

“If you don’t know where you’re going, any road will get you there”

“If there’s a doubt, then there is no doubt…Get the FACTS!!”

© | VDiversify.Inc | All Rights Reserved 13


Step 2 Define The Problem

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 14


Objective

To define the extent of the Problem and its effects in quantifiable terms, resulting in a narrower
focus for Containment and Root Cause-finding efforts

Supporting Concepts

1 5W2H 2 Pareto Diagrams 3 Control Charts 4 Is/Is Not Analysis 5 Check Sheets

Define The Problem

“A Problem well stated is a Problem half-solved”

1 Rarely will a problem description be complete/final at the beginning of the 8D process


2 Problem cannot be completely described until it is well understood
> Problem Description should be revised and updated to incorporate new Facts / Data
3 Quantify the gap between what “is” and what “should be”

© | VDiversify.Inc | All Rights Reserved 15


Supporting Tools

1 Customer Complaints 4 Comparative Analysis

2 5W2H a Is / Is Not
b Table of Facts
3 Data Collection

a Flow Diagram 5 Formulate Problem Statement

b Collect Data (Attribute & Variable) a Include Benchmark


c Stratify (Checksheets & Paretos) b Incorporate All Important Facts
d Statistical Data (SPC & Cpk, etc) c Concise & Precise

1 Customer Complaints

• Describe The Symptoms experienced by the Customer (i.e. User) in their terms

• Ensure the Complaint is clearly and fully understood

a Direct Customer Contact (Ask clarifying Questions)


b Customer Representatives may be on the Team
c Understand the Problem from the Customer’s Viewpoint

© | VDiversify.Inc | All Rights Reserved 16


2 5W2H

Characterize the Problem for further Analysis through 5W2H:

Identify Who is associated with the Problem. Which Customer(s) are Complaining?
Who? Which Internal Group(s) are Complaining?

Describe the Problem adequately. What is the Defect and Gap from “Target”? What
What?
Part or Object is involved? Does the Severity of the Problem vary?

If the Defect occurs on a Part, where is the Defect located? Use a Location Check
Where? Sheet / OPL. Where was the Defect found (geographically)? What is the geographic
distribution of Complaints?

Identify the Time when the Problem started and Past History (Trends). Do all
When? Production Shifts experience the same Frequencies? What time of the Year does the
Problem occur? When did the non-conformance occur? What was the Operating
Time? What Shift? What Season?

Define Why this is a Problem for the Customer or Organization. Translates “How
Why? Big” (see next slide) into Total Business Impact

In what mode of Operation was the Problem discovered? What Procedures were
How? being used? What Environmental Conditions were present?

How Big? Quantify the extent and Severity of the Problem (Quantity, Percent, Cost, DPPM, etc)
© | VDiversify.Inc | All Rights Reserved 17
3 IS / IS-NOT TOOL

Search:

Search for a comparative basis (act like a Detective, include similar Parts / Situations).
Put Boundaries around the Problem to narrow the Search for a Root Cause. Ask numerous
Questions and gather as much Data as possible to establish the “Facts” of the Problem

a Who is experiencing the Problem?


b Where was the Discrepancy observed?
c Where on the Part is the Defect?
d When was the Issue observed?
e How many Bad Parts are in the System?
f Who could be experiencing the Problem but is not?
g Where could the Issue have been observed but was not?
h Where on the Part could the Defect be but is not?
i When could the Issue have been observed but was not?
j How many Bad Parts could be in the System but are not?

© | VDiversify.Inc | All Rights Reserved 18


3 IS / IS-NOT TOOL (Continued….)

Known Facts: Make a Table of the Facts discovered in the Search


Get Info
# Is Is Not On
a What is the Object with the Defect? What Could be, but Is Not, the Object with the Defect?
b What is the Defect? What could be, but Is Not, the Defect?
c Where is the Object with the Defect Where could the Object with the Defect be observed,
Observed? but Is Not?
d Where is the Defect on the Object? Where could the Defect be on the Object, but Is Not?
e When was the Object with the When could the Object with the Defect first have
Defect First observed? been observed, but was Not?
f When was the Object with the When could the Object with the Defect have been
Defect been observed since then? observed since then, but was Not?
g When is the Defect First observed When could the Defect first be observed in the
in the Cycle of the Object? Cycle of the Object, but is Not?
h How many Units of the Object have How many Units of the Object could have the
the Defect? Defect, but do Not?
i How much of each Unit is affected? How much of each Unit could be affected, but Is Not?
j How many Defects are on each Unit? How many Defects could be on each Unit, but are Not?
k What is the Trend? What could be, but Is Not, the Trend?

© | VDiversify.Inc | All Rights Reserved 19


Identify Differences

Ask Questions to understand what is the difference between the “Is” and “Is Not” conditions:

a Helps to focus the thoughts towards the specific problem area


b Avoids trying to “boil the ocean” by making problem scope more manageable
c Important, but often overlooked step in process

Ask, “What Changed?”

No Changes – No New Problems

Problems appear because something has changed. The search for the Root Cause is a search for changes
Ask, “What Changes have occurred?”

• What Changes have occurred in the Plant?


• What New Suppliers are being used?
• Have any New Operators been hired?
© | VDiversify.Inc | All Rights Reserved 20
Ask, “What Changed?” (Continued….)

• Has New Material been used? A New Batch?


• Is the Process Capability the same as usual?
• Was the Weather or Environment or Surroundings unusual when the problem occurred?

Develop Problem Statement

The Problem Statement is the expression of the difference between what should have happened and what
actually happened
• Includes the baseline or benchmark for Good Performance
• Contains reference to One Problem only
• Each Problem is unique and need to be clearly understood in order to be solved
• Should include information from all of the 5W2H Sections

Common Pitfalls

Common Pitfalls when writing Problem Statements include:


• Problem Statement is too general (lacks detail and specifics). A general Problem is difficult to solve
correctly

© | VDiversify.Inc | All Rights Reserved 21


Common Pitfalls

Common Pitfalls when writing Problem Statements include:


• Problem Statement is too general (lacks detail and specifics). A general Problem is difficult to solve
correctly
• Problem Statement describes a Root Cause instead of Problem Effects
• Don’t get into a Root Cause debate at Step 2
• Step 4 is for determining the Root Cause
• Step 2 is for clearly describing the Problem to be solved and quantifying the effects on downstream
Users or Customers
• Embedding a Solution in the Problem Statement. When we embed a Solution into the Problem
Statement
• Steps 5 and 6 are for Solutions (Corrective Actions)
• Don’t get locked into a decision before all Facts are known

Problem Statement with Embedded Solution Revised Problem Statement

Revise Order Processing Procedures to remedy Frequent delays and errors in Processing Orders
recent delays in Processing Customer Orders for all Customers during the last 2 Months

How could this statement be improved further?…

© | VDiversify.Inc | All Rights Reserved 22


Step 3 Implement Containment Actions

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 23


Objective

To Define, Implement and Verify the Effectiveness of Temporary Actions to isolate Customers from
the effects of the Problem

Supporting Concepts & Methods

1 Manufacturing Records 2 Histograms 3 Control Charts

Implement Containment Actions

Containment Actions Are:

1 Intended to Protect a Customer from effects of a Problem


2 A Temporary Fix to buy Time for Root Cause Analysis and C/A Implementation (“Stop The Bleeding”)
3 Not Cost Effective (use Good Business Sense and Judgement when choosing)
4 Quick Fixes designed only to Address the Effect of a Problem (usually Detection-based)
5 Must remain in-place until Permanent C/A Implemented

© | VDiversify.Inc | All Rights Reserved 24


Containment Actions Are (Continued….):

6 Must include a Review of Product at all Phases (see details below)


• Step applies to all Quality issues, not just Product Returns

Material / Product Locations (Containment)

a Raw Material
b Semi-finished Goods (WIP)
c Finished Goods
d At Customer
e At Supplier
f In Transit (from Supplier or to Customer)
g Shipping and / or Receiving Dock
h In Transit (from Supplier or to Customer)
i Materials on Order (Future Shipments from Supplier)

Do not consider Containment Action a


Danger!!
Permanent Solution to a Problem!

© | VDiversify.Inc | All Rights Reserved 25


Common Containment Actions:

a 100% Inspection to Sort out Defects


b Stop Production from a known Source of the Problem
c Purchase Parts rather than make in-house
d Single Source to one rather than Multiple Suppliers
e Use back-up Tooling (fewer cavities/nests)
f Others?
Containment Follow-up

After implementing Containment Actions, Verify their Effectiveness by measuring effects in quantifiable
terms:
• The Effectiveness of the Containment Action must be monitored to ensure proper Protection of the
Customer is maintained
• The benefit of a Containment Action must last until the Root Cause is identified and Permanent
Corrective Action is implemented
• Decision making Tools are used in this step to ensure proper thought is given when choosing the
Actions
• Risk Assessment is an important step during the Decision - Making Process

© | VDiversify.Inc | All Rights Reserved 26


Interim Containment Process

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Buy Time

Interim Containment is a legitimate method to buy time


Containment Actions Compare To The Band Approach

Interim Containment Characteristic Band Aid Approach


X Attack Symptoms X
X Added Costs X
X Monitored During Use
X Documented
X Effectiveness Verified
X Replaced By Effective CAR

Interim Containment Liabilities


1. May be forgotten and remain in effect
Caution!! 2. Costly due to Sort / Re-work
3. Not necessarily 100% Effective
4. Risks must be assessed(Customer, Plant, etc.)

© | VDiversify.Inc | All Rights Reserved 28


Step 4 Identify Root Causes

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 29


Objective

To Identify and Test Potential Causes using the Problem Description and Test Data to isolate and
verify the Root Cause

Supporting Concepts & Methods

1 Brainstorming 2 C/E Diagrams 3 3L5W (3-Leg 5 Why) 4 Histograms


5 Control Charts 6 Capability Studies 7 Gauge R&R 8 Scatter Diagrams
9 Design of Experiments 10 FMEA’s

Types of Root Cause

2 Types of Root Cause:


1 “Occurrence Root Cause”
• A breakdown in Prevention Activities (e.g.: Training, Drawings and Fixtures, etc…)
• The specific Local Cause that resulted in the specific Problem reported

© | VDiversify.Inc | All Rights Reserved 30


2 “Escape Root Cause”
• A breakdown in an Inspection / Detection Operation
• Explains Why the Defect / Problem was allowed to “Escape” to a downstream operation
(e.g.: Next Manufacturing Step or Customer)

Both Types of Root Causes must be addressed:


• Only addressing “Occurrence” allows similar Causes to continue to Escape to the
Customer (appears to be a Repeat Occurrence)
• Only addressing “Escape” leaves unnecessary Wastes (e.g.: Scrap / Re-work) in the
System

Data Input
Data Input Data Input
Data Input Data Input

Is / Is Not
The Fact Funnel Differences
Changes Noted
Hypothesis Testing
Likely Causes
Root Cause

© | VDiversify.Inc | All Rights Reserved 31


Brainstorm Potential Causes

A good way to produce a maximum amount of Ideas is to conduct a Brainstorming Session:


• Cause-and-Effect Diagram (C/E Diagram) is an excellent Tool to assist in Brainstorming for Causes
• All Possible Causes of the Problem should be identified
• The more detailed the C/E Diagram, the greater chance the Root Cause will be included

All Likely, Potential, and even Improbable Causes discussed in the Meeting should appear on the Fishbone
(Cause and Effect) Diagram
Cause And Effect Diagram

Possible Causes For Non-Conformance Possible Causes For Non-Detection

Material Machine Man Material Machine Man

Problem

Mother Method Measurement Mother Method Measurement


Nature Nature

© | VDiversify.Inc | All Rights Reserved 32


Ask 5 Why’s?

Review Symptoms – or Effect – of the Problem. To drive your Team’s understanding from the Effect
to the Causes, Ask, “Why?” Five times! Ensure that at-least a minimum of 3 Why’s are Asked!

Example: Machine Stoppage Typical One Why Exchange:


“Why did the machine stop?” “Fuse blew due to an overload.”
Corrective Action: Replace the Fuse: End of Problem?

5 Why Exchange:

Problem: Machine Stopped

1 Why? Fuse Blew (Overload)

2 Why? Lubrication Inadequate

3 Why? Pump Not Working

4 Why? Axle Damage

5 Why? Impurity In Pump


Corrective Action: Install a Filter on the Lubricator Pump

Ask “Why?” until the answer is not known or can’t be controlled…, then proceed with the investigation

© | VDiversify.Inc | All Rights Reserved 33


Ask 5 Why’s? (Continued…)

This Tool allows the User to reduce the Likelihood of Solving Effects, rather than the base Problem
itself

• Is this a good Permanent Solution to the Problem?


• Could we have asked “Why?” Once More?
• Does a Filter on the Lubrication Pump act as a Permanent Solution?
Hint: What must you do with a Filter? (Clean / Replace)
How did the Impurity get into the Fluid or Pump?

3-Leg 5-Why Analysis Work Sheet

Enhances basic 5-Why Tool. Use all (3) Paths to thoroughly investigate Why the Specific
Non-conformance occurred, Why it was Not Detected by Process Controls, as well as Why the overall
governing System, Policies, Procedures, or Process allowed this Non-Conformance (and perhaps
others like it) to occur. Check continuity of logic by reading back using the “Therefore” Test.

© | VDiversify.Inc | All Rights Reserved 34


Verification Criteria:
The underlying Root Cause has been reached
only when the Final Why satisfies this Criteria:
• It initiates and Causes the event we are seeking to explain
• It is directly controllable
• The elimination of that Root Cause will result in the elimination or reduction of the Problem
© | VDiversify.Inc | All Rights Reserved 35
Select Root Cause

Interpret data and develop potential hypothesis:

• Many different ideas may exist as to what the True Cause of a Problem is

Compare all Hypothesis to Is / Is Not Data (Investigation Facts):

• The True Cause will have all facts either supporting the explanation of being unrelated
• Any Fact refuting a hypothesis means that either the Fact is incorrect (bad data) or the hypothesis needs
revision

Continue Research as needed:

• Verify / Validate Facts in Question


• Revise hypothesis or identify Cause interactions

Always applies to “Occurrence” Root Cause, but can also apply to


“Escape” Root Cause

© | VDiversify.Inc | All Rights Reserved 36


Be Willing To Re-Evaluate

Many have the mistaken belief that Data-Oriented Problem Solving consists of collecting relevant
Data, Analysing the Results, and determining the Correct Solution. After Data is collected, new
questions arise, and original assumptions may change. More than one iteration is usually
necessary to find the Root Cause. The Path is not a Straight Line, but rather a Spiralling one.

Verification

Turn It On …… Turn It Off …….

Through Experimentation (or Simulation), Verify that the real Root Cause has been found. It should
be possible to create and eliminate the Problem by installing and removing the Cause

The True Root Cause should be able to explain all of the Data and
Facts collected up to this time

© | VDiversify.Inc | All Rights Reserved 37


Step 5 Develop & Verify Solution

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 38


Objective

To select from alternative Solutions to the Problem and Verify that the Problem Causes are
eliminated, without introducing New Problems

Supporting Concepts & Methods

1 Brainstorming 2 Risk Assessment 3 Capability Studies 4 Decision Matrix


5 Gauge R&R 6 Control Charts

Choose Verify Corrective Actions

• Corrective Action Decision Criteria is established through the Decision making process
• Objectively evaluate each Possible Action against a predetermined Decision Criteria
• Prove that the Corrective Action (or combination of actions) will eliminate the Problem
• Conduct Verification Tests
• Remove Containment temporarily
• Only Normal Production influences should be present
• Establish indicators to ensure the Defect is eliminated with high confidence
© | VDiversify.Inc | All Rights Reserved 39
Verify The Solution

It is Critical to Verify that the Solution will eliminate the Problem


• Review should happen before implementation of the Corrective Action
• Prove that the Fix will work as Planned
• No unintended Negative Consequences

Verification Approaches

a Design Verification Testing


b Production Validation Testing
c Bench / Lab Testing
d Simulation

Decision Making Results

1 Describe The End Results


• What is the Overall Objective that must be achieved?

© | VDiversify.Inc | All Rights Reserved 40


2 List the Decision Criteria
• Differentiate between “Needs” and “Wants”
• Pros and Cons must be measurable and realistic
• Make sure you cover all the bases and your Criteria represent all areas (Time, Money, Law, People,
Production, etc)
3 Identify the Potential Solutions
• Identify all the Choices you have that may work • Make certain all Ideas are included
• Balance reactive (inspection-based) and Preventive (error-proofing) activities
4 Evaluate the Potential Solutions
• Rank Options against identified Criteria • Identify any Potential Risks of each Solution
• Assess the Probability of the Risk occurring and the Seriousness to your Decision if it did occur
5 Choose a Solution or Set of Solutions
• Use results of Assessment (prior step) • See next Slide for Decision Making Worksheet
• A robust Solution must consider:
- Cost - Timing - Effectiveness - Implementation Issues - Potential Side Effects

Select the option which provides the results you want to


create and has acceptable risk connected with it

© | VDiversify.Inc | All Rights Reserved 41


Step 6 Implement Corrective Actions & Validate Corrective Actions

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

© | VDiversify.Inc | All Rights Reserved 42


Objective

Develop implementation Action Plan:


• Define Actions, Responsibilities, Timing, and required Support
• Define Prevention and Protection Actions. Involves both Action Planning and immediate Validation of
Actions

Supporting Concepts & Methods

1 PDCA Process 2 Process Flow Charts 3 Control Charts 4 Standard Work


5 Capability Studies 6 Control Plans 7 FMEA’s 8 Error Proofing

PDCA Cycle

Plan

Act Do

Check

© | VDiversify.Inc | All Rights Reserved 43


Plan:

Develop Plan for implementing specific Actions

a What Documentation needs to be Updated?


• Work Instructions, Drawings, Control Plans, FMEA’s, Computer Programs, etc

b What People need to be retrained?


• Operators, Inspectors, Engineers, other Support Personnel, etc
c What Organizations need to be notified?
• Internal Departments, Suppliers, Customers, etc
d What New Problems are presented by Changes and how will they be addressed?
• FMEA, Risk Assessment, etc
e Who owns each Task and What is the Targeted Implementation Date?
f How will Progress be Tracked?
g Develop Contingency Plans if Problems are encountered
h When will Containment Actions be removed?

© | VDiversify.Inc | All Rights Reserved 44


Do:

Execute the Plan

a Use existing Control Processes


• Document Control
• Engineering Change (ECO / ECR)
• Customer Notification or Process Change (PCN)
• Supply Chain Processes
• Training Processes
b Identify the Effective Date of Changes
• Operators, Inspectors, Engineers, other Support Personnel, etc

Program Management Tools

• Gantt Charts (High Level)


• Task Lists (Detail Level)
• Report Outs Even a Great Plan can fail, if not executed properly

© | VDiversify.Inc | All Rights Reserved 45


Check:

Review Process to ensure things are working according to Plan

• Track Progress and determine Resources needed to meet Commitment Dates


• Review Performance results to ensure Improvements are being realized
• Review Costs to ensure Financial Impacts are in-line with expectations
• Ensure that no unintended Consequences are happening (Quality, Efficiency, Safety, etc)

Act:
Make necessary adjustments as needed

• Reapply Containment Actions if Problems still present and revise Corrective Actions (back to
Problem Solving and “Plan” Phase)
• Deploy Resources in different way to get execution back on track
• Move on to Next Opportunity if everything is complete and achieving desired results

Remember:

Corrective Actions remove the Root Cause of the Problem, not just the Effect.
Corrective Actions are Permanent. The Problem should not be able to return.

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Step 7 Prevent Problem Recurrence

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

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Objective

To modify the Methods, Equipment, Materials, Process Procedures and Management Systems and
Practices to prevent related problems from occurring (same or similar issues)

Supporting Concepts & Methods

1 Process Flow Charts 2 Standard Work 3 Error Proofing 4 FMEA’s


5 Control Plans

Types of Preventive Actions

a Sustain the Gains for Current Improvements


• Update Procedures / Documentation, Training, Fixtures, Error-Proofing, etc

b Similar Problems within the same Work Area


• Apply improvements to prevent Similar Problems from occurring
• Use FMEA to help identify Opportunities (e.g.: Multiple Causes for a Single Failure Mode / Symptom)

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Types of Preventive Actions (Continued….)

c Same or Similar Problem in another part of the Organization


• Apply Improvements to prevent future Problems
• Learn from prior Mistakes / Problems
• Share the Learning

Lack of Prevention Leads To a Cycle of Waste

Constantly working on Past Concerns


(Fire-Fighting)

Errors Delays, Time Absorber


Patchwork Solutions (Fixing Problems)

Emotions High, Lack of Clear


Stress Priorities

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Step 8 Congratulate Project Team & Effectiveness Monitoring

Problem Discovered ! Problem Solved !

Congratulate Project Team &


8 Effectiveness Monitoring

7 Prevent Problem Recurrence

Implement Corrective Actions &


6 Validate Corrective Actions

5 Develop & Verify Solution

4 Identify Root Causes

3 Implement Containment Actions

2 Define The Problem

1 Initiate Project Team Quality Concepts & Methods


Support These 8 Steps

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Objective

To recognize all the team members for their Individual and Collective Efforts and develop a climate
for On-going Improvements

Supporting Concepts & Methods

1 Employee Involvement / Participative Management 2 Interpersonal Communication Skills

Recognize The Team

If Recognition is not given, Team Members are less willing to Participate and are likely to become
Discouraged. Recognition and Feedback is the most Effective Method available to shape Behaviour

“You Get What You Expect”

a Be Specific on Facts of each Individual’s Input


b Sincerity in both Public and Private, Recognition is required to make it Acceptable to the Recipient
If You Don't Believe It, The Team Member Won’t Either
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Congratulate The Team

Recognize the Team’s Collective Efforts (both Past and Present) in Solving the Problem
and show Appreciation for Individual Contributions.
Team Members are in the best Position to begin this process

a People respond favourably to sincere, thoughtful Recognition


b Recognition makes People “Feel Good” about Themselves, their Achievements, and the
Organization that took the Time to Acknowledge them
c Recognition provides Very Positive Reasons for Team Members to Participate in Future Efforts

Forms of Recognition

Top Management Letter Plaque

a Deliver at home (Family) a For Outstanding Contribution


b Post on Bulletin Board (Co-Workers) b Personal, and Specific to Problem Solved
c Place in Personnel File (Management)
Recognition needs can differ greatly
Performance Review from person to person.

a Include as Major Contribution


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THANK YOU…
Any Questions….?

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