8-D Problem Solving and Root Cause Analysis
Course Description
Overview:
Provide class participants with the skills need to identify, contain, investigate and solve problems. Class will include a variety of tools to support the problem solving process.
CLassroom oriented team training:
One-day (8-hour course) designed to provide participants with problem solving and root cause analysis skills utilizing the 8D method of Problem Solving. Training utilizes a Case Study in a classroom environment. There is a 16 hour “hands-on” class available that includes working through actual organization problems.
Audience
Quality professionals, supervisors/managers, engineers, senior technicians as well as cross-functional members of the organization. Students will require minimal math skills (adding, subtraction, calculating percentages.) Class is very interactive, and as such, class size limited to 15 participants.
1 or 2 Days
Course Outline:
Overview of Problem Solving
- Class Objectives
- Benefits of Problem Solving as a Methodology
- Problem Solving System Terms and Vocabulary
- 8D Model for Problem Solving and Tools for Each Step
8-D Step 1 – Select the Team
- Step 1 Team Charter Worksheet
- Problem Definition
- Establishing the Team
- Team Roles and Responsibilities
- Project Justification
8-D Step 2 –Understand the Problem
- 5 W’s & 2 H’s
- Gemba
- Baseline Data
- Crafting the Problem Statement
8-D Step 3 Containment Action
- Understanding Problem Impact and Risk
- Containment Action Worksheet
8-D Step 4 Root Cause Analysis
- Brainstorming Techniques
- Cause and Effect Analysis (Ishikawa Diagram)
- 5 Why’s
- Using Risk Tools, such as FMEA to Support Causal Discussions
- Process Flow Charting and Process Flow Analysis
- Pareto Analysis
- Trend Analysis
- Scatter Diagrams (correlation analysis)
8-D Step 5 Solution Development and Selection
- Solution Selection Matrix (Pugh Method)
- Risk Analysis and the Law of Unintended Consequences
- Verifying Corrective Action Prior to Implementation
8-D Step 6 Solution Implementation and Verification
- Developing the Corrective Action Plan
- Hawthorne Effect
- Evaluation of effectiveness
Step 7 Prevent Recurrence and Solution Globalization
- Process Documentation
- Training Plans
- Poka Yoke
- Revisiting Risk Tools, such as FMEA
- Definition of Ongoing Metrics and Responsibilities
- Globalization Opportunities
8-D Step 8 Congratulate the Team
- Management Presentations
- Team Recognition Process
- Lessons Learned
Issuance of Final Exam