Product defects are not uncommon but an organization must act quickly to eliminate them. This will ensure customers have a good experience and the brand doesn’t suffer. In the event of a complaint, an organization can rely on the analysis of an 8D report sample to address errors and improve quality.
The 8D methodology is a structured and systematic approach to problem-solving. From an 8D problem-solving example it’s clear that it not only identifies a problem but also recognizes the weaknesses in the system. Analysis of an 8D report example prevents future occurrences of similar issues.
Examples Of 8D Reports
An 8D problem-solving example shows the strength of this model lies in its methodology, structure and discipline. Organizations can effectively use an 8D report example to analyze defects, its root causes and ways to implement corrective actions.
Let’s have a look at these 8D reports.
8D Problem-Solving Report Example
An organization had a problem with holes appearing in its metal cast toy parts. They found that about 3% of their last batch received complaints after operations due to pin-hole defects. An analysis was submitted after the purchase head asked for a full 8D report example. Here’s a look at the 8D report sample that was submitted.
D1: Names of team members, team leader and manager.
D2: The problem reported by the customer is described by answering the following questions:
- What is the problem?
A pin-hole defect
- Who reported it?
Tulip Pvt Ltd
- When did it occur?
Seen in the last batch
- Why did it happen?
Due to a defect in the casting base
- How much production is affected?
3% of the products are defective.
These questions aim to simplify their approach to problem-solving.
D3: Once the problem is defined, the defective parts are segregated.
D4: The root cause of the problem is identified by answering the following questions:
- Why is there a pin-hole defect?
- Why are core problems arising?
- Why wasn’t the core cured properly?
- Why was drying/curing time not modified?
These questions reveal that curing time was not validated and that was the root cause of the problem.
D5: A permanent corrective plan is recommended to the quality assurance engineer. It is proposed that product and process should be validated for new drying time.
D6: Permanent corrective actions are implemented. 10 samples are collected. Product and process characteristics of each sample are checked.
D7: Preventive measures are recommended to ensure the problem doesn’t recur.
D8: Team and individual contributions are recognized by the manager. The team leader and team members are rewarded for their efforts.
8D Problem-Solving Example
An organization received customer complaints about shrinkage on an automobile part. The management demanded a thorough analysis based on an 8D problem-solving example. Here’s the 8D report sample that was submitted:
D1: A team is created with supply team members, team leader and manager.
D2: A customer complaint is used to describe the problem. The problem is established by answering the following questions:
- What is the complaint?
Shrinkage on sump.
- When was it seen?
In the last batch.
- Why did it happen?
Due to a defect in the entrance area.
- Who reported the problem?
- How much production is affected?
These questions allow the team to devise a containment plan.
D3: As a containment action the team decides to stop consignments and segregate the good parts immediately.
D4: To identify the root cause, the team has to answer the questions defining the problem. They are:
- Why was there a shrinkage at the ingate area?
- Why were high pouring temperatures used?
- Why was the pyrometer reading incorrect?
- Why was the pyrometer condition not checked?
The root cause of the problem is revealed to be a faulty pyrometer.
D5: As a permanent corrective plan, periodic checking of the pyrometer is suggested to the maintenance supervisor.
D6: Permanent corrective action is implemented and pyrometers are scheduled for weekly checks.
D7: Periodic checking and proper maintenance of pyrometers are factors to prevent a recurrence.
D8: The team effort is recognized. The manager and team are praised for solving the problem.
An 8D report example will show that Root Cause Analysis (RCA) is an integral part of the 8D process. It helps managers establish problem statements, identify potential causes, compare theories and confirm the main cause of a problem. You can establish the root cause in an 8D report example by asking the most relevant questions related to the defect.
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