Corrective Action and 8_D process

1.1 The eight disciplines are:
1.1.1 D0 – Awareness of the Problem . Customer (at the site or in the field) concern or internal (process, product or system) concern.
1.1.2 D1 – Establish the Team. The team is cross-functional, assuring the right knowledge, skills and experience is represented. All perspectives of the problem are represented (the stakeholders). The team size should be manageable to effectively allow decision making and solutions to be implemented in a timely manner. The characteristics of an effective team should include leadership; commitment; clearly defined goals; objectives & responsibilities; trust and respect; authority; effective listening; time management & effective communication skills.
1.1.3 D2 – Describe the Problem. This is a definitive documented statement of the issue. Steps used to document the problem are collecting facts through the “who, what, when, where, why, how and how many” questioning. This part of the process is factual and describes the gap between what “is” and what should be. It is imperative that the true problem is identified to solve it instead of addressing symptoms.
1.1.4 D3 – Initiate Containment. Immediate actions are taken to identify and contain the product to prevent building and shipping additional products. Verification that the potential actions are capable of containing the problem is required. This part of the evaluation process must include analyzing how far reaching the containment actions need to be (ie internal, customer site, in the field, etc.)
1.1.5 D4 – Identify Root Cause. This is the most difficult and critical part of the 8-D process. The inaccurate identification of the root cause will allow the problem to recur. Common tools used to determine root cause are Fishbone Diagrams, Brainstorming (used for formulating ideas of root cause), Experimentation and Process Flow Analysis. Using the “5 Why?” questioning technique, along with visual observation of the process are important factors in this step.
1.1.6 D5 – Identify and Implement Corrective Action. The action(s) taken to eliminate the cause and to prevent recurrence. The corrective actions must align with the identified root causes, at minimum. The last part of this process is to assure a definitive plan for implementing the actions.
1.1.7 D6 – Verify Corrective Action Effectiveness. The team establishes the verification plan to measure the effectiveness of the implemented actions. This is a data driven process.
1.1.8 D7 – Identify and Implement Action(s) to Prevent Recurrence. This step in the process is the preventive action taken to prevent the problem from recurring again within the workcell, across lines or products in other sites, or globally. Corrective action is a reactive activity while preventive action is a proactive activity. Preventive opportunities are in the updating of Design & Process FMEA’s, Control Plans and Design for Manufacturability. Leveraging and sharing lessons learned within workcells, sites and products and across the globe are where the most benefit is realized.
1.1.9 D8 – Recognize the Team. The efforts and accomplishments are recognized. The CAR is officially closed out.