Probleme solving Process

Problem solving forms part of thinking. Considered the most complex of all intellectual functions, problem solving has been defined as higher-order cognitive process that requires the modulation and control of more routine or fundamental skills . It occurs if an organism or an artificial intelligence system does not know how to proceed from a given state to a desired goal state. It is part of the larger problem process that includes problem finding and problem shaping.

Problem solving is of crucial importance in engineering when products or processes fail, so corrective action can be taken to prevent further failures. Perhaps of more value, problem solving can be applied to a product or process prior to an actual fail event ie. a potential problem can be predicted, analyzed and mitigation applied so the problem never actually occurs. Techniques like Failure Mode Effects Analysis can be used to proactively reduce the likelihood of problems occurring. Forensic engineering is an important technique of failure analusis which involves tracing product defects and flaws. Corrective action can then be taken to prevent further failures.

''Eight Disciplines Problem Solving'' is a method used to approach and to resolve problems - typically employed by quality engineers or other professionals. Also known as 8D, 8-D Problem Solving, G8D or Global 8D.

8 Disciplines (8Ds) in Problem Solving

D1: Use a Team: Establish a team of people with product/process knowledge.

D2: Define the Problem: Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how and how many (5W2H)for the problem.

D3: Implement and verify Interim Actions: Define and implement containment actions to isolate the problem from any customer.

D4: Identify and Verify Root Causes: Identify all potential causes that could explain why the problem occurred.

D5: Choose and verify Permanent Corrective Actions (PCAs): Through pre-production programs quantitatively confirm that the selected corrective actions will resolve the problem for the customer.

D6: Implement and validate PCAs :Define and Implement the best corrective actions.

D7: Prevent recurrence: Modify the management systems, operation systems, practices and procedures to prevent recurrence of this and all similar problems.

D8: Congratulate your Team : Recognize the collective efforts of the team. The team needs to be formally thanked by the organization.


History

The development of a team oriented problem solving strategy, based on the use of statistical methods of data analysis, was developed at Ford Motor Company. The executives of the Powertrain Organization (transmissions, chassis, engines) wanted a methodology where teams could work on recurring problems. No existing methodology or government standard filled these requirements. Hence, in the summer of 1986, the assignment was given to develop a manual and a subsequent course that would achieve a new approach to solving tough engineering design and manufacturing problems. The manual for this methodology was documented and defined in "Team Oriented Problem Solving"(TOPS) and was first published in the winter of 1987. Several pilots of the course and content where given to a wide range of organizations across Ford Motor company. This approach to problem solving was quickly adopted by all areas within Ford Motor Company and has been the basis for their approach to probems for over 20 years.

8D has become a standard in the Auto, Assembly and other industries that require a thorough structured problem solving process.

The 8D Problem Solving Process is used to identify, correct and eliminate problems.

The methodology is useful in product and process improvement. It establishes a standard practice, with an emphasis on facts. It focuses on the origin of the problem by determining Root Cause.

Usage

Many common disciplines are typically involved in the "8D" process, all of which can be found in various textbooks and reference materials used by [[Quality Assurance]] professionals. For example, an "Is/Is Not" worksheet is a common tool employed at D2, and a "Fishbone Diagram" or "5 Why Analysis" are common tools employed at D4.

The 8D process originally arose out of Ford Motor Company, where it went through several iterations over several decades, including "TOPS" or "Team Oriented Problem Solving". In the late 1990's, Ford developed a revised version of the 8D process, officially titled "Global 8D" (G8D) which is the current global standard for Ford and many other companies in the automotive supply chain. The major revisions to the process are as follows:

Addition of a D0 (D-Zero) step as a gateway to the process. At D0, the team documents the symptoms that initiated the effort along with any Emergency Response Actions (ERAs) that were taken before formal initiation of the G8D. D0 also incorporates standard assessing questions meant to determine whether a full G8D is required. The assessing questions are meant to ensure that in a world of limited problem-solving resources, the efforts required for a full team-based problem-solving effort are limited to those problems that warrant these resources.

Addition of Escape Point to D4 through D6. The idea here is to consider not only the [[Root cause]] of a problem, but equally importantly, what went wrong with the control system in allowing this problem to escape. Global 8D requires the team to identify and verify this Escape Point (defined as the earliest control point in the control system following the Root Cause that should have detected the problem but failed to do so) at D4. Then, through D5 and D6, the process requires the team to choose, verify, implement, and validate Permanent Corrective Actions to address the Escape Point.

Along with these revisions to the process, Ford developed a web-based software package, called Global 8D, to facilitate implementation of this process, standardize reporting, maintain a searchable repository of problem-solving efforts, and enhance team collaboration. Presently, this software is only available within Ford, although plain 8D Software is available to the public from other companies.

Recently, the 8D process has been employed extensively outside the auto industry. As part of Lean initiatives, it is used within Food Manufacturing, High Tech and Health Care industries.