Ford 8Ds For Problem Solving
Ford 8Ds is a lean Manufacturing tool. Originally developed at Ford Motor Company, Eight D was introduced in 1987 in a manual titled "Team Oriented Problem Solving" (TOPS). This course was written at the request of senior management of the automaker's Power Train organization, which was facing growing frustration at the same problems that were recurring year after year. The focus of this system was to use this approach in a team environment. Teams are to be cross-functional and include members from both the manufacturing organizations as well as design engineering.
The Ford 8Ds are most effective in dealing with chronic recurring problems, primarily defects or warranty issues. They were never intended to replace or stand as a systemic quality system. The 8Ds' focus was to deal with problems and discover the weaknesses in the management systems that allowed the problem to occur In the first place. The real benefit would come by changing how management decisions allowed the problem to happen. The problem is merely a symptom of a greater systemic management issue.
Global 8D problem solving is made up of a detection cycle and a prevention cycle. It defines a corrective action methodology.
Increasingly, these days, companies practicing lean manufacturing are requiring their employees to also understand the 8-Discipline approach (Eight D) to team-based problem solving. These essentially present a standard methodology for data analysis and statistical thinking as follows:
- D - Use a team approach
- D - Describe the problem
- D - Implement and verify interim containment actions
- D - Define and verify root causes
- D - Verify the correction action(s)
- D - Implement permanent corrective actions
- D - Prevent problem recurrence
- D - Congratulate the team
For most manufacturing organizations, routine problem solving will not improve the product and/or process. A more systemic overall quality initiative, such as six sigma or another method is still required.
