8D Problem Solving Process Report Template (Word DOCX)

DESCRIPTION

The 8 Disciplines of Problem Solving (8D) is a problem solving methodology designed to uncover the Root Cause of a problem, develop containment actions to protect customers, and then implement corrective action to prevent similar problems from occurring in the future. The 8D problem solving process is a detailed, team oriented approach to solving critical problems in the production process. It is incredibly useful in product and process improvement initiatives.

The 8D problem solving process was developed the Ford Motor Company developed (originally known as Team Oriented Problem Solving, TOPS) in the 1980s. The early usage of 8D format proved so effective that it was adopted by Ford as the primary method of documenting problem solving efforts. Ford continues to use 8D quality reports today.

In current times, the 8D Problem Solving Process has become a standard in many industries as problem solving or improvement process, as internal Corrective Action Request (CAR) Process or as Supplier Corrective Action Request (SCAR) Process.

This Word document, 8D Problem Solving Process Report, is a fully customizable 8D report template. It is developed by Operational Excellence Consulting LLC.

This 8D form follows the standard 8D report format, allowing you to capture and document each of the 8-steps of the 8D process:

Step 1: Establish the Team – Select and establish a team of people with product/process knowledge.

Step 2: Describe the Problem – Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many for the problem.

Step 3: Develop Interim Containment Actions – Define and implement containment actions to isolate the problem from any customer.

Step 4: Define and Verify Root Causes and Escape Points – Identify all applicable causes that could explain why the problem occurred. Also, identify why the problem was not noticed at the time it occurred. All causes shall be verified or proved, not determined through brainstorming or similar exercises. We can leverage 5 Whys, Cause & Effect diagrams, or other Lean tools to map causes against the effect or problem identified.

Step 5: Choose and Verify Permanent Corrective Actions – Through pre-production programs, quantitatively confirm that the selected correction will resolve the problem for the customer.

Step 6: Implement and Validate Permanent Corrective Actions – Define and implement the best corrective actions (CA).

Step 7: Prevent Recurrence – Modify the management systems, operation systems, practices, and procedures to prevent recurrence of this and all similar problems.

Step 8: Approval & Team Recognition – Recognize the collective efforts of the team. The team needs to be formally thanked by the organization.

This 8D template is a companion to the The 8D Problem Solving Process training guide developed by Operational Excellence Consulting LCC, available on the Flevy marketplace.

The complete The 8D Problem Solving Process training guide is a 200+ slide PowerPoint presentation. It also includes a number of Lean tools. Specifically, The key problem solving tools included in the 8D Problem Solving Process are Pareto Chart, Histogram, Run Chart, 5 Whys, Is-Is Not Matrix, Process Flow Chart, Process Variables Map, Fishbone Diagram, Comparative Analysis, Scatter Plot, Box Plot, Process Failure Mode and Effects Analysis (FMEA), Root Cause Theory Testing, Mistake Proofing, and Process Control Plan. Full details can be found here.

This template includes detailed sections for documenting root cause analysis and implementing corrective actions. It also features fields for tracking the status and effectiveness of each action, ensuring accountability and thorough follow-up.

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Source: Best Practices in Lean Template, Problem Solving, 8 Disciplines, 8D Word: 8D Problem Solving Process Report Template Word (DOCX) Document, Operational Excellence Consulting LLC