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

  • D6 Implement and Verify Corrective Actions (Continued)
    • 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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