8D Approach to Problem Solving
Training by
MBizM Group (LeanSix Sigma)
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- The 8D (Eight Disciplines) Problem Solving Methodology is a step-by-step problem solving methodology pioneered by Ford Motor Company through its Team Oriented Problem Solving Global 8D Process. It is a highly effective approach to finding root causes, development of proper actions to eliminate root causes, and implementation of permanent corrective action. The 8D process uses a combination of effective techniques and tools to focus a cross functional team through a very detailed analysis of the problem. When followed diligently, 8D will lead to the discovery of the root causes and possible solutions with consideration of cost, timing, effect on customers, and the impact on the organization.
- In this 2-day practical workshop, participants will learn through a step by step instructional process of preparation, establishing a team, brainstorming, to systematically analysing and preventing problems from recurring. In addition, participants will learn the practical problem solving tools required by the 8D process. Through the workshop, participants will be able to appreciate why implementing and using an 8D problem solving methodology using a multi-disciplined team is beneficial and important, especially when meeting customer expectations. The 8D is a problem-solving methodology for product and process improvement. It is structured into eight disciplines, emphasizing team synergy. The primary difference between 8D and other problem-solving approaches is the emphasis on involving a TEAM versus doing it all yourself.
- The 8D Process is a problem solving method for product and process improvement. It is structured into 8 steps (the D's) and emphasizes team. This is often required in automotive industries. The 8 basic steps are: Define the problem and prepare for process improvement, establish a team, describe the problem, develop interim containment, define & verify root cause, choose permanent corrective action, implement corrective action, prevent recurrence, recognize and reward the contributors.
Outline
Section 1 - 8D Overview
- Team Problem Solving Principles
- Process Description (8 Step Process)
- Team Structure (Cross Functional Team)
- Inductive vs Deductive Problem Solving
- Change-induced Problems
- Never-achieved Problems
- Brainstorming Rules
- Ishikawa / Fishbone / Affinity Diagram
- Control Chart
- Relationship between 8D and FMEA
- Why technique and 3x5 Why technique
- Error-Proofing / Poka Yoke
- Incident Mapping - Interfaces and Noise Factors
- D0 - Prepare (Plan) for the 8D
- Problem Symptom
- Quantified Symptom
- Criteria for 8D Continuance
- D1 - Form the Team
- Roles and Responsibilities
- Team Preparation
- Agenda and Rules
- Core Team and SMEs
- D2 - Problem Description
- Repeated Why
- Affinity Diagram
- Is/Is Not
- Incident Map
- Break-up session on Problem Statements and Brainstorming
- Break-up session on Problem Description Development
- D3 - Interim Containment Action (ICA)
- D4 - Root Cause Analysis (RCA) and Escape Point
- Human Factors (Operator Error)
- Comparative Analysis
- Root Cause Analysis
- Root Cause Verification
- Escape Point
- Workshop on Root Cause Theories
- D5 - Permanent Corrective Action (PCA)
- Methods for Selecting PCA
- Error-Proofing
- Verification of PCA
- D6 - Implementation and Validation of PCA
- Plan, Do, Study, Act (PDSA) Implementation Plan
- Change Management
- Stakeholders
- Validation Criteria and Sample Size
- D7 - Preventive Action
- Processes and Procedures
- Lessons Learned
- D8 - Closure and Congratulate the Team
- Archive of Documents
Speaker/s
Dr. Satnam Singh | Experienced LSS Deployment in Europe & India
Dr. Satnam Singh graduated from Liverpool John Moores University (UK) with a Bachelor's Degree in Mechanical Engineering. He then furthered his studies at Coventry University in UK & was awarded with a Master's Degree of Science
in Engineering & Manufacturing Management. Dr. Satnam then continued to study for his doctorate and was awarded with a PhD in Engineering & Manufacturing Management.
Dr. Satnam has been actively involved in the field of Continual Improvement activities since the beginning of his tertiary education. While accomplishing his Master's Degree in the United Kingdom, he had been extensively trained
in Lean Systems & Six Sigma whilst working as a Project Manager for a Multinational Corporation (MNC) in the UK for 14 years. During his stay with the MNC in the UK, Dr. Satnam was tasked with the responsibility of promoting and implementing Lean & Six Sigma
within the Organization and throughout Europe. Due to his extensive exposure to Lean & Six Sigma Management Systems, he was invited by the company's European Subsidiaries to conduct in-house training, project consultations, and strategic planning in the area
of Six Sigma implementation. Dr. Satnam is known as a Visiting Lecturer in Infosys India.
Mr. Harbans | Experienced LSS Deployment in Samsung & Asia Pacific
Mr. Harbans Singh, is a graduate of University of East London and holds a Bachelor's Degree (Hons.) in Information Technology majoring in Software Engineering. He is certified as a Six Sigma Black Belt trained by Juran Institute (USA & Korea) under the supervision of Samsung Electronics Asia Pacific. Mr. Harbans has gained over 12 years of working experience both in the manufacturing & service industries.
Mr. Harbans has extensive experience in performing statistical analysis by using statistical software (MINITAB) and various quality tools. Harbans was involved in Innovating Supplier Processes using QDC (Quality, Delivery & Cost) improvement and Improving Supplier Processes by utilising OEE & Lean concepts. He's major achievement would include the development of Six Sigma Green Belts & Six Sigma Black Belts within Samsung Electronics Asia Pacific Region. Furthermore, he mentored Six Sigma Yellow Belt, Green Belt & Black Belt projects that contributed to total cost savings of USD $15 million during the past 6 years. He also has extensive experience in developing and conducting Six Sigma Champions Training, Black Belt, Green Belt & Yellow Belt training programmes for Private Companies, major Government Linked Companies (GLCs) in Malaysia & many other Government Agencies.
Dr. Muraliraj | Expert in LSS, Process Improvement & Lean Enterprise Solutions
Dr. Muraliraj holds a doctorate degree from University of Malaya (Malaysia) overlapping the field of Quality Management, Continuous Improvement & Innovation. His research base is centred around continuous improvement philosophies such as Lean & Six Sigma and how their application & management can potentially morph towards innovation.
Specialised in process mapping, optimization, cost reductions, and deploying process excellence strategies, Dr. Muraliraj has been involved in process excellence projects, performance improvements, and change management in shipping, oil & gas, engineering, and IT industries for more than 7 years. One of his recent successes includes training & coaching Lean Six Sigma in a national multi-industry corporation involving tens of personnel ranging from various designations which led to substantial financial savings besides sustainable operational excellence.
Mr. Muhammad Faisal | Expert in LSS Specialized in Manufacturing & Process Improvements
Mr. Faisal graduated from University of Technology (UTM), Malaysia with Bachelor's in Chemical Engineering & later pursued his Master's in Business Administration at University Utara Malaysia. He started his career as an engineer in a renowned MNC & was later enrolled in Lean & Six Sigma as a practitioner & was selected as a trainer. His role as a senior staff allows him to work with front-line & middle management.
While working as a coordinator in Innovation Team, he was liaising with top management such as Factory Managers & Directors and had contributed to establishing company strategies toward achieving the mission & vision. While enduring his career as a continuous improvement specialist, he was extensively involved in process improvement initiatives, Six Sigma & Lean Manufacturing. He has profound experience in manufacturing, engineering, & training.
Mr. Balasharmila Rao | Senior BPM Consultant
Mr. Bala is a Mechanical Engineering graduate from the National University of Singapore (NUS) with a specialization in Offshore Oil & Gas Technology. Parallel to his undergraduate study, he has completed a three-year Design Centric Programme (DCP) under NUS, culminating in a successful Electric Vehicle (EV) conversion project with a peer-reviewed IEEE Journal paper publication.
After an industrial attachment with Schlumberger & maiden career start with Halliburton in the oilfield equipment design vertical, Mr. Bala returned to Kuala Lumpur in 2016 and joined YTL Communications (YTLC) in the Facilities Management Department. He developed the department's first suite of Standard Operating Procedures (SOPs) for Operations & Maintenance, coordinated the department's audit compliance for ISO27001: 2013- Information Security Management System (ISMS) for YTLC's Data Centers, and improved diverse aspects of maintenance operations such as Preventive & Corrective Maintenance Management, Rounds & Readings & Facility Management Service Requests. He is also instrumental in improving YTLC's overall National Department of Occupational Safety & Health (DOSH) Audit rating from a Grade 'D' in March 2018 to a Grade 'A' in October 2018 with further recommendation for Ministerial Award Competition participation. Mr. Bala holds certifications in Lean Six Sigma Green & Black Belt, ISO9001: 2015 (QMS) Requirements, Train The Trainer (PSMB TTT/27657), and Oil & Gas Law (BAC).
Ms. Anissa Ridzuana | Trainer & Facilitator
Anissa Ridzuana is a PETRONAS University of Technology (UTP) graduate with a Bachelor’s Degree in Chemical Engineering (Hons.), majoring in Process Plant Engineering. During her internship at Top Glove Corporation Bhd, she studied the performance of cartridge filters to reduce total suspended solids and aided in reducing latex wastage in the production of gloves. She participated in Plant Design for Resource Recovery of Industrial Wastewater project in her university. She consolidated the process and focused on the compliance of the plant towards Health, Safety, and Environment (HSE) aspects and any local environmental regulations.
Besides, she was involved in developing a prediction model to predict chemical compound (hydrate formation) temperature. She also strategized a business plan to generate income for the American Institute of Chemical Engineers UTP Student Chapter (AIChE-UTP-SC).
During her university days, she was involved in many activities including secretariat, director and, assistant project director roles that enhanced her leadership skillset. Anissa also excels and has an exceptional track record in her academics and curricular activities. She was awarded Dean’s list for three consecutive semesters and represented her faculty in netball tournaments.
Mr. Harbans | Experienced LSS Deployment in Samsung & Asia Pacific
Mr. Harbans Singh, is a graduate of University of East London and holds a Bachelor's Degree (Hons.) in Information Technology majoring in Software Engineering. He is certified as a Six Sigma Black Belt trained by Juran Institute (USA & Korea) under the supervision of Samsung Electronics Asia Pacific. Mr. Harbans has gained over 12 years of working experience both in the manufacturing & service industries.
Mr. Harbans has extensive experience in performing statistical analysis by using statistical software (MINITAB) and various quality tools. Harbans was involved in Innovating Supplier Processes using QDC (Quality, Delivery & Cost) improvement and Improving Supplier Processes by utilising OEE & Lean concepts. He's major achievement would include the development of Six Sigma Green Belts & Six Sigma Black Belts within Samsung Electronics Asia Pacific Region. Furthermore, he mentored Six Sigma Yellow Belt, Green Belt & Black Belt projects that contributed to total cost savings of USD $15 million during the past 6 years. He also has extensive experience in developing and conducting Six Sigma Champions Training, Black Belt, Green Belt & Yellow Belt training programmes for Private Companies, major Government Linked Companies (GLCs) in Malaysia & many other Government Agencies.
Dr. Muraliraj | Expert in LSS, Process Improvement & Lean Enterprise Solutions
Dr. Muraliraj holds a doctorate degree from University of Malaya (Malaysia) overlapping the field of Quality Management, Continuous Improvement & Innovation. His research base is centred around continuous improvement philosophies such as Lean & Six Sigma and how their application & management can potentially morph towards innovation.
Specialised in process mapping, optimization, cost reductions, and deploying process excellence strategies, Dr. Muraliraj has been involved in process excellence projects, performance improvements, and change management in shipping, oil & gas, engineering, and IT industries for more than 7 years. One of his recent successes includes training & coaching Lean Six Sigma in a national multi-industry corporation involving tens of personnel ranging from various designations which led to substantial financial savings besides sustainable operational excellence.
Mr. Muhammad Faisal | Expert in LSS Specialized in Manufacturing & Process Improvements
Mr. Faisal graduated from University of Technology (UTM), Malaysia with Bachelor's in Chemical Engineering & later pursued his Master's in Business Administration at University Utara Malaysia. He started his career as an engineer in a renowned MNC & was later enrolled in Lean & Six Sigma as a practitioner & was selected as a trainer. His role as a senior staff allows him to work with front-line & middle management.
While working as a coordinator in Innovation Team, he was liaising with top management such as Factory Managers & Directors and had contributed to establishing company strategies toward achieving the mission & vision. While enduring his career as a continuous improvement specialist, he was extensively involved in process improvement initiatives, Six Sigma & Lean Manufacturing. He has profound experience in manufacturing, engineering, & training.
Mr. Balasharmila Rao | Senior BPM Consultant
Mr. Bala is a Mechanical Engineering graduate from the National University of Singapore (NUS) with a specialization in Offshore Oil & Gas Technology. Parallel to his undergraduate study, he has completed a three-year Design Centric Programme (DCP) under NUS, culminating in a successful Electric Vehicle (EV) conversion project with a peer-reviewed IEEE Journal paper publication.
After an industrial attachment with Schlumberger & maiden career start with Halliburton in the oilfield equipment design vertical, Mr. Bala returned to Kuala Lumpur in 2016 and joined YTL Communications (YTLC) in the Facilities Management Department. He developed the department's first suite of Standard Operating Procedures (SOPs) for Operations & Maintenance, coordinated the department's audit compliance for ISO27001: 2013- Information Security Management System (ISMS) for YTLC's Data Centers, and improved diverse aspects of maintenance operations such as Preventive & Corrective Maintenance Management, Rounds & Readings & Facility Management Service Requests. He is also instrumental in improving YTLC's overall National Department of Occupational Safety & Health (DOSH) Audit rating from a Grade 'D' in March 2018 to a Grade 'A' in October 2018 with further recommendation for Ministerial Award Competition participation. Mr. Bala holds certifications in Lean Six Sigma Green & Black Belt, ISO9001: 2015 (QMS) Requirements, Train The Trainer (PSMB TTT/27657), and Oil & Gas Law (BAC).
Ms. Anissa Ridzuana | Trainer & Facilitator
Anissa Ridzuana is a PETRONAS University of Technology (UTP) graduate with a Bachelor’s Degree in Chemical Engineering (Hons.), majoring in Process Plant Engineering. During her internship at Top Glove Corporation Bhd, she studied the performance of cartridge filters to reduce total suspended solids and aided in reducing latex wastage in the production of gloves. She participated in Plant Design for Resource Recovery of Industrial Wastewater project in her university. She consolidated the process and focused on the compliance of the plant towards Health, Safety, and Environment (HSE) aspects and any local environmental regulations.
Besides, she was involved in developing a prediction model to predict chemical compound (hydrate formation) temperature. She also strategized a business plan to generate income for the American Institute of Chemical Engineers UTP Student Chapter (AIChE-UTP-SC).
During her university days, she was involved in many activities including secretariat, director and, assistant project director roles that enhanced her leadership skillset. Anissa also excels and has an exceptional track record in her academics and curricular activities. She was awarded Dean’s list for three consecutive semesters and represented her faculty in netball tournaments.
Schedules
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Our Mission: “To help our customers design strategies, approaches and breakthrough processes through the execution of Lean, Six Sigma and Quality Methodology, and thus turn the customer’s organization into a leader in its field”
Our Vision: “To be known as an innovative and creative centre for delivering effective Business Process Improvement training courses and consultancy services.”
MBizM Sdn. Bhd. (MBizM™) offers a range of Six Sigma, Lean, Quality and Soft Skills, Training and Consultancy Programmes. MBizM™ was founded to improve the competitive position of its customers by promoting the implementation of Business Process Improvement Methodologies such as Six Sigma and Lean whilst equipping the participants with a range of quality management tools and soft skills. MBizM™ is a young and dynamic company where the company was founded by individuals that were actively involved in a wide range of projects in organizations mainly from the industrial, services and public sectors.
MBizM™ provides expertise in practical tools, techniques and methodologies for attaining and maintaining competitive position and quality leadership. We know how to provide tailored solutions to meet specific customer needs while delivering world-class services in areas of Lean Six Sigma. Our trainers have decades of experience in delivering these courses to various industries in Malaysia and Overseas. Courses are delivered by certified consultants who have spent years in the industry, solving real-life problems in organizations. Our courses are designed to be dynamic. They are combined with theory, lectures, case studies, exercises, games and workshops. ...
