How do you keep 8D problem solving simple and practical without compromising its rigor and structure?

1 Define the problem

The first step of 8D problem solving is to define the problem clearly and accurately. This helps you to focus on the real issue and avoid jumping to conclusions or solutions. To define the problem, you need to gather relevant data, such as customer complaints, defect rates, process parameters, or test results. You also need to describe the problem in terms of what, where, when, how much, and how often. A useful tool for defining the problem is the problem statement, which summarizes the problem in one or two sentences.

2 Contain the problem

The second step of 8D problem solving is to contain the problem temporarily until you find the root cause and implement the permanent solution. This prevents the problem from spreading or causing more damage to your customers, products, or processes. To contain the problem, you need to identify and isolate the affected units, materials, or areas. You also need to implement short-term actions, such as rework, repair, quarantine, or recall. A useful tool for containing the problem is the containment plan, which outlines the actions, responsibilities, and deadlines for containing the problem.

3 Form the team

The third step of 8D problem solving is to form the team that will work on the problem. This ensures that you have the right people with the right skills, knowledge, and authority to solve the problem. To form the team, you need to select the team members, assign the roles and responsibilities, and establish the communication and reporting mechanisms. You also need to define the scope, objectives, and timeline of the project. A useful tool for forming the team is the team charter, which documents the team's mission, vision, and rules.

4 Find the root cause

The fourth step of 8D problem solving is to find the root cause of the problem. This helps you to eliminate the problem at its source and prevent it from recurring. To find the root cause, you need to analyze the data, identify the potential causes, and verify the actual cause. You also need to validate the root cause by testing your hypothesis and replicating the problem. A useful tool for finding the root cause is the fishbone diagram, which helps you to brainstorm and organize the possible causes into categories.

5 Choose the solution

The fifth step of 8D problem solving is to choose the solution that will fix the problem permanently and prevent it from happening again. This helps you to improve your customer satisfaction, product quality, or process performance. To choose the solution, you need to generate, evaluate, and select the best alternative based on criteria such as feasibility, effectiveness, cost, and risk. You also need to plan how to implement the solution, including the resources, tasks, and milestones. A useful tool for choosing the solution is the decision matrix, which helps you to compare and rank the alternatives based on their scores.

6 Implement the solution

The sixth step of 8D problem solving is to implement the solution that you have chosen. This helps you to execute your action plan and achieve your desired results. To implement the solution, you need to communicate, train, and support the stakeholders who are involved or affected by the change. You also need to monitor, measure, and document the outcomes and impacts of the solution. A useful tool for implementing the solution is the PDCA cycle, which helps you to plan, do, check, and act on your solution.

7 Prevent recurrence

The seventh step of 8D problem solving is to prevent recurrence of the problem. This helps you to sustain your improvement and avoid future issues. To prevent recurrence, you need to identify and eliminate the root causes of similar or potential problems in other areas or processes. You also need to update or create the standards, procedures, or policies that reflect the best practices and lessons learned from your solution. A useful tool for preventing recurrence is the FMEA, which helps you to analyze and reduce the failure modes and effects of your process or product.

8 Celebrate success

The eighth and final step of 8D problem solving is to celebrate success. This helps you to recognize and reward your team's efforts and achievements. To celebrate success, you need to review and summarize your project's performance, benefits, and challenges. You also need to share and celebrate your results and learnings with your customers, management, and other stakeholders. A useful tool for celebrating success is the recognition letter, which expresses your appreciation and gratitude to your team members and sponsors.