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8d: Problem Solving Worksheet

Tracking Number: |Customer Number: |Response Due Date: | | |8-D is a quality management tool and is a vehicle for a cross-functional team to articulate thoughts and provides scientific determination to details of problems | |and provide solutions.Organizations can benefit from the 8-D approach by applying it to all areas in the company.The 8-D provides excellent guidelines allowing | |us to get to the root of a problem and ways to check that the solution actually works.

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Rather than healing the symptom, the illness is cured, thus, the same | |problem is unlikely to recur. |Step |0 |1 | |1 |Establishing the Team: |Team Goals: | | |Establish a small group of people with the process/ product | | | |knowledge, allocated time, authority and skill in the required | | | |technical disciplines to solve the problem and implement corrective |Team Objectives: | | |actions. | |Department | |Name | |Skills | |Responsibility | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |2A |Problem Definition |Sketch / Photo of Problem | | |Provides the starting point for solving the problem or | | | |nonconformance issue. Need to have “correct” problem description to | | | |identify causes.

Need to use terms that are understood by all. | | | | | | | |Part Number(s): | | | |Customer(s): | | | |List all of the data and documents that might help you to define the | | | |problem more exactly? | | |Action Plan to collect additional information: | | | |Prepare Process Flow Diagram for problem | | | |use a separate sheet if needed | | |2B |IS |IS NOT | |Who |Who is affected by the problem? |Who is not affected by the problem? | | | | | | | | | |Who first observed the problem? |Who did not find the problem? | | | | | | | | | | |To whom was the problem reported? | | | | | |What |What type of problem is it? |What does not have the problem? | | | | | | | | | | |What has the problem (part id, lot #s, etc)? |What could be happening but is not? | | | | | | | | | |What is happening with the process & with containment? |What could be the problem but is not? | | | | | | | | | | |Do we have physical evidence of the problem? | | |Why |Why is this a problem (degraded performance)? |Why is it not a problem? | | | | | | | | | |Is the process stable? | | | | | | |Where |Where was the problem observed? Where could the problem be located but is not? | | | | | | | | | | |Where does the problem occur? |Where else could the problem be located but is not? | | | | | |When |When was the problem first noticed? |When could the problem have been noticed but was not? | | | | | | | | | |When has it been noticed since? | | | | | | |How Much/|Quantity of problem (ppm)? |How many could have the problem but don’t? |Many | | | | | | | | |How much is the problem costing in dollars, people, & time? |How big could the problem be but is not? | | | | | |How Often|What is the trend (continuous, random, cyclical)? |What could the trend be but is not? | | | | | | | | | | |Has the problem occurred previously? | | | | | |2C |Problem Description | | |(based on the information gathered so far, provide a concise problem description) | | | | | | | | | | | | | 3 |Developing Interim Containment Actions | | |Temporary actions to contain the problem and “fix” until permanent correction is in place – document actions in Action Item Table | | | | | | | | | | |4A |Identifying & Verifying Root Cause | | |Analyze for “Root Cause” of the problem.

Identify and verify the Escape Point | | | | | |Brainstorm the possible causes of the problem | | | | |4A |Cause and Effect Diagram | | | | | | | | | | | | | | | | | | | | | | | | |circle the most likely contributors (a maximum of three) from each side. |4B |5 Why Analysis | | | |Ask – Why did this happen? | | | | | | | |Ask – Why did this happen? | | | | | | | |Ask – Why did this happen? | | | | | | |Ask – Why did this happen? | | | | | | | |Ask – Why did this happen? | | | | | | | |4C |Action Plan | | |Based on the team’s discussions.

Begin to complete the Root Cause Action Plan to verify and validate the root causes and test the escape point. | | |Document this on the Action Item Table | | | | | | | | | | | | | |5 |Identify Permanent Corrective Actions | | |solutions that address and correct the root cause. Solutions determined to be the best of all the alternatives.

Document and verify the Permanent | | |Corrective Action (PCA) in the Action Item Table | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |6 |Implementing & Validating the PCA | | |Implement and validate to ensure that corrective action does “what it is supposed to do. ” Detect any undesirable side effects. Document this on the | | |Action Item Table. Return to root cause analysis, if necessary | | | | | | | |7 |Preventing Recurrence | | |determine what improvements in systems and processes would prevent problem from recurring.

Ensure that corrective action remains in place and successful | | | | | | | |7A |Address Similar Systems | | |Process / Item | | |Who Responsible | | |When | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | 7B |Review the following documents / systems | |Document |Who Responsible |Completion Date | | | |Planned |Actual | |Management System Manual | | | | |Manufacturing Work Instructions | | | | |Inspection Work Instructions | | | | |Process Flow Charts | | | | |Process Control Plans | | | | |Design FMEA | | | |Process FMEA | | | | |Gages | | | | |PPAP | | | | |Engineering Change Approval | | | | | | | | | | | | | | | | | | | |8 |Congratulate Your Team | | |Use all forms of employee recognition and document as necessary | | | | | |Celebrate successful conclusion of the problem solving effort | | |Formally disengage the team and return to normal duties | | | | |Was this problem solving exercise effective? Has it been verified with a follow-up? | |Yes |Signature / Title / Date |Findings | |No | | | | | | | | | | | | | | | | | | |Action Item Table | |Actions |Implement & Verify Actions | Action # |Problem |Containment / Corrective Action |How Verified |Action |Who Responsible |Planned |Actual |Status | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | ———————– Problem People Materials Machine Method Environment Measurement Measurement Environment Method Machine Materials People Why did it get out? How is it made?

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