8D Problem Solving | Mastering 8D in Lean Six Sigma with Example (2)

Summary

In this continuation of the 8D problem-solving series, the video explores steps D4 to D8, emphasizing the importance of identifying root causes to prevent recurring issues. Through an example, the process of asking successive 'whys' is showcased, underpinning the significance of fact-based analysis in developing permanent corrective actions. The steps highlight common pitfalls and mitigation strategies to ensure sustainable improvements. The crucial role of implementing, validating, and preventing reoccurrence of solutions is discussed, culminating with recognizing team efforts for continued motivation.

Highlights

• D4 focuses on root cause identification using methods like the '5 Whys'. 🔍
• D5 involves developing data-driven and feasible corrective actions. 🚀
• Common mistake: Relying on gut feelings rather than data for solutions. 🙅
• D6 stresses on implementing and validating the corrective actions effectively. ✅
• D7 ensures measures to prevent reoccurrence are in place, like SOP updates. 📜
• D8 focuses on recognizing the team's effort and documenting the process. 🏆

Key Takeaways

• Identifying root causes is essential for long-term solutions, not just temporary fixes. 🔍
• Using tools like Fishbone and FMEA can help in fact-based root cause analysis. 🛠️
• Effective corrective actions should be data-driven and sustainable. 📊
• Regular audits and updates to SOPs can prevent problem reoccurrences. 🔄
• Recognizing team efforts boosts morale and foster a culture of improvement. 🌟

Overview

Welcome back to our exciting deep dive into the 8D methodology, where today, we unravel steps D4 to D8 using our ongoing example. Discover why identifying the root causes is crucial to preventing recurring issues and how tools like the '5 Whys' enhance our understanding. Root cause analysis isn’t just for the tech-savvy—it’s for anyone keen on sustainable problem-solving! 🌟

Moving from identifying issues to implementing solutions, we spotlight steps D5 and D6. Here, solutions aren’t just picked off the shelf; they’re tailor-made, data-driven, and fully validated. Tune into the segment to see how effective execution can reduce defects and foster client satisfaction. Don’t miss the common pitfalls people stumble into—avoid them to ensure your solutions stick! 🚀

Lastly, we round off with preventing issues from rearing their ugly heads all over again with D7 and D8. By updating SOPs and recognizing team efforts, you cement improvements into the organization's culture, paving the way for continuous growth. This is more than just wrapping things up—it’s about building resilient teams ready for tomorrow's challenges! 🏆

Chapters

• 00:00 - 00:30: Introduction and Recap of D0 to D3 The chapter introduces the topic by recapping the steps D0 to D3 in the 8D process discussed in a previous video. It mentions that the previous video included examples of these steps and highlighted common mistakes and mitigation strategies. The chapter then transitions to the next steps in the 8D process, specifically focusing on step D4, which involves identifying the root cause. The importance of this step is emphasized as the discussion prepares to delve into the subsequent steps of the 8D methodology.
• 00:30 - 02:00: D4: Identify Root Cause The chapter "D4: Identify Root Cause" discusses the importance of addressing the true root causes of a problem to prevent its recurrence. It highlights that merely addressing symptoms leads to temporary solutions and recurring issues. The chapter introduces the concept of root cause analysis, using it as an example to demonstrate how it can be conducted effectively. The explanation is supplemented by an analysis process demonstrating how asking successive 'why' questions can reveal the underlying causes of defects. For instance, defects might occur due to misalignment in engine components, which further investigation might attribute to part variation.
• 02:00 - 03:30: D5: Develop Permanent Corrective Action The chapter focuses on developing permanent corrective actions through root cause analysis. It discusses the application of the 'Five Whys' method to drill down into problems such as inconsistent material quality from suppliers. The team finds that the issues stem from a lack of standardized inspection and receiving processes and a deficiency in supplier quality control processes. The successive questioning enables the identification of root causes which can be verified for accuracy.
• 03:30 - 05:00: D6: Implement and Validate Permanent Corrective Action This chapter discusses the process of connecting probable root causes to previous causes using logical connections, specifically through the use of the word 'therefore'. It emphasizes the importance of ensuring a logical connection between cause and effect to accurately identify the root cause of a problem. The chapter also highlights common mistakes in the analysis process, such as jumping to conclusions without a fact-based analysis and stopping at symptoms instead of addressing the actual root cause.
• 05:00 - 06:30: D7: Prevent Reoccurrence The chapter titled 'D7: Prevent Reoccurrence' discusses strategies to avoid repeating mistakes by implementing mitigation plans using tools like fishbone diagrams and Failure Mode and Effect Analysis (FMEA). It emphasizes the importance of validating root causes with data, process mapping, and hypothesis testing. Once root causes are identified and validated, the subsequent step involves developing permanent corrective actions, highlighting its significance in ensuring permanent elimination of issues rather than temporary control.
• 06:30 - 07:30: D8: Recognize the Team The chapter discusses the need for data-driven and sustainable solutions to problems, emphasizing the importance of recognizing the team in these efforts. The core issue identified is a lack of supplier quality control processes. To address this, the chapter suggests implementing supplier quality audits and revising incoming inspection criteria. Additionally, the installation of automated sensors for detecting misalignment in engine components is proposed as a preventive measure.
• 07:30 - 08:30: Conclusion and Final Thoughts This chapter, titled 'Conclusion and Final Thoughts,' discusses common mistakes made in solution selection, such as relying on gut feelings rather than data and overcomplicating solutions that are not feasible. To avoid these errors, it suggests using tools like a pub matrix or cost-benefit analysis for selecting the best solution. Additionally, it emphasizes the importance of ensuring alignment with business goals and process capabilities to effectively develop solutions.

8D Problem Solving | Mastering 8D in Lean Six Sigma with Example (2) Transcription

• 00:00 - 00:30 Hello friends, welcome back. In the first video on 8D, we explored steps D0 to D3 with an example along with common mistakes and how to mitigate them. If you missed it, here is the link to watch it. Now, let's continue learning the next steps in AD using the same example. Once we implemented the interim containment action, we need to move to the next step which is D4. Identify root cause. Why is this step important? Finding and
• 00:30 - 01:00 addressing the true root causes prevents reoccurrence of the problem. Addressing only the symptoms lead to the temporary fixes and recoccurring issues. Now let's talk about the root cause analysis for the problem that we have initiated as an example. We can use the fi analysis here. Like the first question can be why are the defects occurring? The answer is misalignment in the engine component fitting. Why is the misalignment happening? Because variation in part
• 01:00 - 01:30 dimensions. Why is there variation? Inconsistent material quality from suppliers. Why supplier quality inconsistent? No standardized inspection and receiving. And we can extend it to the next level by asking the question why no inspection lack of supplier quality control process. By asking successive wise, the team is able to identify the root cause. We can also verify the root cause by starting
• 01:30 - 02:00 at the probable root cause and connecting it to the previous cause using therefore. If there is a logical connection between each pair of statements back to the problem, then you have likely found the root cause. This is very important step as a part of it. Now let's talk about what are the common mistakes that people are doing as a part of this D4. Jumping to conclusions without factbased analysis stopping at symptom instead of the actual root cause
• 02:00 - 02:30 to avoid those mistakes. We can have the mitigation plans like use tools like fishbone diagram and FME. We can validate those root causes with data and process mapping as well as by using hypothesis testing. After identification of the root cause and validating it, we can move to the next step which is D5. Develop permanent corrective action. Why is this step important? This step ensures the issue is eliminated permanently rather than just control
• 02:30 - 03:00 temporarily. Solution must be datadriven and sustainable. Let's talk about the problem that we have initiated. What are the solutions that we can implement after identification of the root cause? As we have identified the root cause as lack of supplier quality control process, we can initiate supplier quality audit and revision of the incoming inspection criteria. We can also initiate the installation of the automated sensor to detect the misalignment in engine components in
• 03:00 - 03:30 real time. Let's talk about what are the common mistakes that people are doing as a part of this step. D5 selecting solution based on gut feeling rather than data. over complicating solutions that are not feasible. To avoid those mistakes, we can have the mitigation plan like use pub matrix or costbenefit analysis to select the best solution. We can also ensure the alignment with business goals and process capabilities. After developing the
• 03:30 - 04:00 permanent corrective action, now it's time to go to the next step which is D6. Implement and validate permanent corrective action. Why is this step important? Even a well-designed solution can fail if not executed correctly. Validating the corrective actions ensures they work as expected. In the example that we have initiated, we can have the implementation plan like supplier audits completed within 4 weeks and automated sensor installed in 6
• 04:00 - 04:30 weeks. We can also validate those results by looking at the data like defect rate reduced from 15%age to 3%age within 2 months and customer complaints dropped by 60%age. This is also validating the effectiveness of the corrective actions that we have executed. Let's talk about the common mistakes that people are doing as a part of this D6. poor execution leading to inconsistent results and failing to track the impact
• 04:30 - 05:00 with KPIs. To avoid these mistakes, we can have the mitigation plans like conduct pilot testing before full scale implementation and we can use the control charts to monitor post implementation performance. After implementing and validating the permanent corrective action, let's move to the next step which is D7 prevent reoccurrence. Why is this step important? Sustaining the improvements ensures that we are going to avoid the reoccurrence of the
• 05:00 - 05:30 problem. Let's talk about this step. With respect to the problem that we have initiated, we can have the preventive measures like updated SOPs for receiving inspections, supplier contracts updated with strict quality requirements and employee training programs are implemented. What are the common mistakes that professionals are doing as a part of this step D7? Not updating SOPs and training documents and lack of ongoing process monitoring. To avoid
• 05:30 - 06:00 those mistakes, we can have the mitigation plan like implement standard work instructions. Conduct regular audits and refresher training. Once we ready with the preventive measures to prevent the reoccurrence of the problem, we can move to the next step which is D8. Recognize the team. Why is this step important? Recognizing the team's effort boost motivation, encourages a culture of continuous improvement and reinforces teamwork. Let's talk about this step for
• 06:00 - 06:30 the example that we have initiated. Team was recognized in a companywide meeting. Case study is documented for future references. What are the common mistakes that professionals are doing as a part of this last step? taking credit at higher management levels instead of recognizing the team and forgetting to document the lessons learned. To avoid those mistakes, we can have the mitigation plan like conduct a formal recognition event, create a forum to
• 06:30 - 07:00 share the best practices for future references. I'm sure with this example you are having the complete clarity on this AD problem solving methodology. Now let's go to the conclusion. Ed is a powerful problem solving framework that ensures issues are resolved effectively and permanently. Avoiding common mistakes at each stage will lead to the better implementation and sustainable process improvements. If you found this entire information valuable, please do not forget to like, comment and
• 07:00 - 07:30 subscribe. Thank you for your valuable time and see you in the next video.