Embed Size (px)
Citation preview
8D REPORT A Step by Step Problem Solving Process
Written by: Siu Wai Au ASQ CSSBB, CQA, CMQ/OE, LBC-Sensei, PMP
1
DOCUMENTATIONDOCUMENTATION
2
Document Detail
Case Number:
Case Title:
Opened Date:
Prepared by:
Reviewed by:
Closed Date:
Verified by:
Approved by:
D1: Team Formation 建立團隊D2: Problem Description 問題描述D3: Immediate Action 即時行動D4: Root Cause Analysis 原因分析D5: Corrective Action 糾正行動D6: Implement and Validate 執行及驗證D7: Prevention 預防措施D8: Closure 總結
3
TABLE OF CONTENTTABLE OF CONTENT
Name 1, Process Engineer, Leader Name 2, Project Manager Name 3, Electrical Engineer Name 4, Electrical Engineer Name 5, Quality Engineer Name 6 , Production Officer
A cross-functional team shall be formed in order to tackle the problem, the team should include subject matter expert (who has relevant process knowledge), as well as the people who familiar with the problem solving tools.
4
D1: TEAM FORMATIOND1: TEAM FORMATION 建立建立團隊團隊
DateDate發生日期發生日期 LocationLocation發生地點發生地點 //場所場所 ProcessProcess制程制程 CustomerCustomer客戶客戶
Product P/NProduct P/N產品產品 Failure RateFailure Rate不良率不良率 OwnerOwner責任人責任人
Problem StatementProblem Statement問題陳述問題陳述 ImpactImpact影响影响
Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many (5W2H) for the problem.
5
D2: PROBLEMD2: PROBLEM DESCRIPTION DESCRIPTION 問題描述問題描述
D2: PROBLEMD2: PROBLEM DESCRIPTION DESCRIPTION 問題描述問題描述Illustrate the problem with Defects Pictures / Flow Chart / Process Mapping / Pareto Chart according to its nature.
6
DD33
D3 Guideline
7
Risk AssessmentRisk Assessment
Understanding of the Problem
Defective Rate
Stop Ship / Stop Build Decision
Containment Action(s)
Immediate Actions
Traceability Data
Affected Affected P/NP/N Stop Ship Stop Ship Date Date Resume Resume
DateDate Stop BuildStop Build DateDate Resume Date
D3: IMMEDIATE ACTION D3: IMMEDIATE ACTION 即時行動即時行動
8
Stop Build / Stop ShipDecide whether stop ship / stop build is required
WhereWhere How ManyHow Many DefectivesDefectives What to doWhat to do WhenWhen
WIP - Shop Floor
FG - Store
Materials - Store
Hubs/ In Transit
Field
End Customer
D3: IMMEDIATE ACTION D3: IMMEDIATE ACTION 即時行動即時行動
9
Containment ActionsTo prevent these problem / defectives from reaching the customer.
DD44
D4 Guideline
5-Why5-WhyCause & Effect DiagramCause & Effect Diagram
Pareto ChartPareto ChartIPO AnalysisIPO Analysis
FMEAFMEAFault Tree AnalysisFault Tree AnalysisStatistical MethodStatistical Method
Team Knowledge
Process Mapping
Process Parameter
Detection Cause(s)
Systemic Cause(s)
Direct Root Cause(s)
Root Causes Analysis (RCA)
Traceability Data
10
D4:D4: ROOT CAUSE ANALYSIS ROOT CAUSE ANALYSIS 根本原因分析根本原因分析5-Why Analysis 五次為甚麼Drilling down into a problem, digging out the root cause
WHY?
WHY?
WHY?
WHY?
Cause of the Problem
Cause of the 1st Cause
Cause of the 2nd Cause
Cause of the 3rd Cause
Cause of the 4th Cause
ProblemWHY?
12
D4: ROOT CAUSE ANALYSIS D4: ROOT CAUSE ANALYSIS 根本原因分析根本原因分析Cause & Effect Diagram 因果圖Brainstorm all the possible causes of the problem, circle the critical & controllable items
Man
MaterialMeasure
PROBLEM
Method
MachineEnvironment• • • • • • •
• • • •
• • • • • • •
• • • •
• • • • •
• • • • • • •
13
Input Process Output
14
Input-Process-Output (IPO) Analysis Identify all possible causes of the problem by listing all the input parameters throughout the processes
D4: ROOT CAUSE ANALYSIS D4: ROOT CAUSE ANALYSIS 根本原因分析根本原因分析
D4: ROOT CAUSE ANALYSIS D4: ROOT CAUSE ANALYSIS 根本原因分析根本原因分析
TypeType Item#Item# Root CausesRoot Causes
Root Cause(Failure Mode) 1
2
Detection 3
4
Systemic 5
6
15
Conclusion of RCA
DD55
D5 Guideline
BrainstormingBrainstormingBenefit-Effort MatrixBenefit-Effort Matrix
Mistake-ProofingMistake-ProofingError-ProofingError-Proofing
ChecklistChecklistDetection Cause(s)
Direct Root Cause(s)
Generation of Corrective Actions
Corrective Actions
16
D5: CORRECTIVE ACTIOND5: CORRECTIVE ACTION 糾正行動糾正行動
17
Benefit-Effort MatrixBrainstorm all the possible SOLUTIONS, select the best solution(s) base on the cost-effectiveness.
BENEFIT
EFFORT
• werwe • ewrew• ewrew• erwe• 2fedv• •
• • • • • • •
• • • • • • •
• • • • • • •
D5: CORRECTIVE ACTIOND5: CORRECTIVE ACTION 糾正行動糾正行動Base on the root causes identified, list the corrective actions that are able to eliminate the root causes permanently. The corrective actions must be feasible and cost-effective.
18
Root Cause # Corrective Action(s) % Effect Est. Completion
Date Owner
1
DD66
D6 Guideline
Hypothesis TestsHypothesis TestsData Collection FormsData Collection FormsSampling Method
Deployed Corrective Actions
Implement & Validation Process
Validated Corrective Actions
19
New ProcessSample Size
Acceptance Criteria
Results
D6: IMPLEMENT & VALIDATE D6: IMPLEMENT & VALIDATE 執行及驗證執行及驗證After the corrective actions are implemented, verify the result to determine the effectiveness of the actions taken.
Sampling Sampling MethodMethod Sample SizeSample Size CriteriaCriteria
Est. Est. Completion Completion
DateDateResultResult Criteria Met?Criteria Met?
20
D7: PREVETION 預防措施DD77
D7 Guideline
BrainstormingBrainstormingBenefit-Effort MatrixBenefit-Effort Matrix
Mistake-ProofingMistake-ProofingError-ProofingError-Proofing
ChecklistChecklistControl ChartsControl Charts
FMEAFMEAControl PlanControl Plan
Systemic Causes
Weakness of Management System
Preventive Actions
Control Plan
21
New Procedure / Policies
History of Similar Cases
Corrective Actions
D7: PREVETIOND7: PREVETION 預防措施預防措施If there are systemic cause identified, modification of the management systems, operation systems, practices, MI, and procedures might required to prevent recurrence of this and all similar problems.
22
Root Root Cause #Cause # Preventive ActionsPreventive Actions % Effect% Effect Est. Completion Est. Completion
DateDate OwnerOwner
D8: CLOSURE D8: CLOSURE 總結總結State the conclusion, why the project can be closed like what are the objectives achieved, what is gained and in what extent, give your lesson learned, and explore the possibility of horizontal deployment.
23
