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8D Problem Solving Process Tools Workshop

Course Length: 16 hours
Training Location: On-site at your facility

Our 8D Problem Solving Process Tools training workshop provides the skills and knowledge needed for solving problems using the Global 8D industry standard model. This workshop provides an emphasis on the practical use of common problem-solving tools and includes technical concepts, classroom discussion, and hands-on exercises. Teams of participants will perform practical exercises, allowing them to implement the theories in a team-oriented atmosphere. The course may be customized to incorporate your company-specific case studies and documentation if you desire.

Course Terminal Objective: 

At the end of this workshop, the participants will be able to lead or participate as an effective team member a team-oriented problem solving effort, using a time-proven structured problem solving strategy (the 8D method) that gets results by: 

  • Solving problems by finding real root causes
  • Taking action that permanently removes the problem

Enabling objectives:

To achieve the terminal objective, the participants will learn to:

  • Describe the benefits of using a structured approach for solving problems.

  • Compare industry standard problem-solving models including 8D, PDCA, and DMAIC.

  • Implement the steps of the 8D process to solve a problem.

  • Identify which problem-solving tools are best used in conjunction with each step of the process.

  • Perform Pareto and IS/IS NOT analyses for problem identification and description.

  • Perform root cause analysis using structured brainstorming, 5 whys, cause and effect (fishbone or Ishikawa), run chart, and scatter diagram analyses.

  • Develop, implement, and verify permanent corrective actions using force field analysis, NGT, action matrix, and error proofing techniques.

  • Explain basic SPC principles including process capability (Cp, CpK).

Each participant will receive a copy of our 125-page Problem Solving Reference Guide and a flash drive loaded with helpful tools, electronic forms, checklists, templates, and case studies that can be used to enhance problem solving activities.

Find out why this 2-day 8D workshop is our most popular course 

 Typical Course Outline and Schedule (16-hr Course)

 Day 1 AM

  What is Problem Solving?

  Why use a structured process?

  PDCA

   Introduction to the 8D Model:

   D0 Prepare for the process

   D1 Use a team approach

   D2 Describe the problem

   D3 Implement and verify containment activity

   D4 Define root cause

   D5 Develop permanent corrective actions  

   D6 Implement and verify corrective actions

   D7 Prevent recurrence

   D8 Congratulate your team

    DMAIC and Six Sigma

    Comparing DMAIC to 8D and PDCA

    8D Documentation and examples

    Problem Solving Tool Selection Matrix

    Selecting the right tool for the job

    D0 Prepare for the Process

   Getting started

   Problem selection

   Pareto charts

Exercise: Create and interpret a Pareto chart

    D1 Use a Team Approach

   Team selection and makeup

Exercise: Form teams and perform initial data collection run for in-class case study

Day 1 PM

  D2 Describe the Problem

   The importance of collecting and interpreting data

   Problem statements and operational definitions

   Flow charts

  Exercise: Use an IS/IS NOT worksheet to develop problem definition

  D3 Implement and Verify Containment Activity

   Containment strategies -Thinking outside the box

   Problems with containment

   Exercise: Identify possible containment strategies

  D4 Define Root Cause

   Root cause analysis methodology

   Structured brainstorming techniques

   Cause and Effect (Fishbone) Diagrams

   Repeated Whys (5 Whys)

  Exercise: Use structured brainstorming methods, and a fishbone diagram to identify and classify possible root causes

Day 2 AM

   Review of homework and case studies

   D4 Define Root Cause (continued from day 1)

Identifying root cause types:

    Cause of occurrence (technical)

    Cause of escape (non-detection)

    Managerial root causes

    Systemic root causes

Exercise: Design a simple experiment to isolate root cause

    Run Charts

    Exercise: Create/analyze a run chart for root cause analysis

   D5 Develop Permanent Corrective Actions

    Developing an Action Plan

    Error Proofing (Poka Yoke)

    Nominal Group Technique

    Exercise: Use NGT to reach consensus on corrective actions - develop PCAs

   D6 Implement and Verify Corrective Actions

    Putting the Action Plan into place

    Action Matrix

    Force Field Analysis

Day 2 PM

    Histograms 

    Modified Scatter Diagrams

    Exercise: Create/analyze a scatter diagram

   D7 Prevent Recurrence

    Identifying recurrence issues

    Leveraging your success for maximum ROI

    Concepts of SPC

    Process Capability (Cp and CpK)

   D8 Congratulate Your Team  

   8D Auditing

    Summary and Wrap-up

 

All APS courses are conducted on-site at our clients' facilities. The course content may be customized to fit your specific needs. For a free quote or for more information on this course, email us at info@aps-online.net or call us at 610-987-4050.

Learn more about our Problem Solving and Quality Services

 

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