8D Problem Solving: What I learnt.
I was surfing the net and came across Bosch’s Supply Chain Academy. Grateful I did. This is what I got from it.
Requirement: Supplier have to remedy failures systematically and sustainable.
Problem Solving (PS) means an integrated approach to the sustainable solution of problems. The term ‘problem’ itself is understood as ‘deviation from a defined target state with an unknown cause’.
Recommended for all failures and on demand by Bosch.
Why do it? / Purpose
Understanding the functional dependencies and relationships of cause and effect in order to avoid reoccurrence of same or similar problems.
When to do it
Whenever a problem has to be solved (acc. above description)
Key Performance Indicator (KPI)
- Reaction time,
- Quality of problem solving,
- Avoidance of mistake repeat
Occurrence of a problem, meaning a deviation of defined target state with unknown cause by Bosch or supplier
- Collection and analysis of facts and figures
- Problem description
- Analysis of cause-effect-relationship
- Root-cause analysis (technical & managerial)
- Definition of measures to solve problem
- Implementation of counter measures
- Close communication regarding activities with Bosch contact
- Problem clearly described and fundamental problem understood
- Root cause and cause-effect-relationship clearly understood
- Proof of effectiveness of counter measures
- Lessons Learned
- D1: Set up a Problem-Solving team.
- D2: Describe the problem.
- D3: Initiate Containment Actions.
- D4: Determine the root Cause.
- D5: Define corrective actions and prove effectiveness.
- D6: Implement Corrective actions and Track Effectiveness.
- D7: Prevent Recurrence of the problem.
- D8: Conduct final meeting.
Sponsor/Champion: The customer who logs in the complain.
8D Team Members.
External Team Members.
Get the Data,facts, figures. Who reported the problem? What is the problem? When did the Problem occur? How? How often?
Containment actions. What are the measures you can put in place?
Root Cause Analysis…
- Technical Root Cause.
- Non-detection root cause.
- Non-prediction root cause.
Occurrence and Deviation.
Risk assessment to drive updates and improvements to estimate potentially defective parts…
Patterns of Occurrence(Erratic, Permanent,Periodical,Seasonal, Etc…)
Techniques for RCA
- 5 why Technique
- Fault Tree Analysis
- Kepner Tregoe
- Six Sigma
- BPS Problem-solving sheet.
Ishikawa Diagram. Cause & Effect Analysis.
→Used to identify & document all potential Causes of problem.
The 5 is just an estimate.Could be more/Less.The technique in real life requires that you continue to ask why until why is Identified.
Define & verify corrective actions to address the root cause of the problem.
Activities Involved: Compiling a limit of all actions that can elimiante the root Cause of the Problem.
- Verifying the effectiveness &consequence of the identified actions.
- Determining & Confirming the “optimal” corrective action(s).
- Creating an action plan including the milestones & responsibilities for implementing the corrective actions.
- Documenting & communicating the corrective actions to the customer.
Failure Mode & Effects Analysis(FMEA), Design Review Based on Failure Mode(DRBFM)
Result|Defined & approved Correction action.
Set milestones →Responsibilities…
Implementation of Corrective action.
→Remove containment actionin D3 as soon as possible!
→Is there supporting data to verify if the Corrective action worked?
D7: Prevent Recurrence:
→Appropriate reasons in Quality Management systems(QMS)
→Transferring experiments to other proceses, Products, locations(Lessons Learned, Yokoten-Japanese that translates to “best practice sharing”)
D8: Final meeting to recognize success of the complemented 8D problem-Solving.
→ Archived completed 8D report.
When? — Pre Deviation. Through out Life cycles.
Collect all Relevant Data: Picture, Graphs, Charts, Flow Charts, Diagrams…
Document 8D Steps:
Use available (IT) Infrastructure — Google sheets, Docs, Etc.
Timeline a typical 8D in Bosch:
8D Evaluation Sheet: I will leave that one out. If you’re interested, you can check out the full online course.
- It took me 3–4 hours to complete, take the test and receive a certificate.
- The course was designed by Robert Bosch GmbH for their suppliers, but I think it would be quite useful to anyone interested in Supply Chain.
- I am not linked to Bosch in any way — yet.