8D (Eight Disciplines) is a team-based, eight-step problem-solving method. It is the standard response format to customer complaints in the automotive supply chain.
The eight steps
- D1: Establish the team
- D2: Define the problem
- D3: Containment and protecting the customer
- D4: Determine the root cause
- D5: Select the permanent corrective action
- D6: Implement and verify the permanent corrective action
- D7: Prevent recurrence and horizontal deployment
- D8: Recognize the team and close
The most frequently skipped points
Confusing D3 with D5. Containment is not a permanent corrective action. Protecting the customer by sorting is D3; ensuring the problem does not recur is D5 and D6.
Not asking “why was it not detected.” In root cause analysis only “why did it occur” is asked; yet why the error escaped your system must also be investigated.
Not doing horizontal deployment. If the same error is possible in similar processes or products, the solution must be carried over there as well.
Reflecting the outputs in the PFMEA and control plan is the closure condition of the corrective action.
Structured problem solving and root cause analysis are practised on your own cases in the CQI-20 effective problem solving training. For field-originated problems, see the CQI-14 warranty management programme.