8D Problem Solving Process Flowchart

Global 8D report - Evaluation Guide Lines

S.N.

GUIDELINES/ CHECKPOINTS

APPLICABLE TOOLS

EVALUATION
Yes/No/NA Comments from Evaluator

2
3

GENERAL / PREPARATORY
Whether concern is logged into the centralized 'Concern Management System' (CMS) in server
and details periodically udapted therein?
Wherever concern is part related, whether supplier G8D is insisted upon?
Whether supplier G8D's are qualitatively evaluated as per this checklist?

Whether team has adequate understanding and knowledge of the overall G8D methodology?

For complex concerns requiring involvement from Field, PD, VD, Quality, SQA, mfg. etc, whether
----G8D's are initiated at multiple levels e.g. System level G8D; Part level G8D etc.?

1
2
3
a
b
c
e
f

D0 - PREPARE FOR PROBLEM SOLVING PROCESS

Has the symptom been clearly defined by the affected parties?
Does the severity, urgency, size and/or complexity of the symptom exceed the ability of one
person to resolve?
Is there need for an Emergency Response Action (ERA)? If yes:
Is the ERA clearly known and documented?
Whether ERA is implemented at all the suspect vehicles/ products at Field, Yard, FG, EOL, mfg
etc.?
Whether details w.r.t. qty., cut off nos., implementation dates etc are captured properly for
vehicles/ products with ERA?
Note : This is required when verification/ validation is mentioned as 'yes'.
Whether the above is communicated to all concerned and affected parties?
Whether adequate supporting data is available & included in G8D report w.r.t. Effectiveness &
implementation of ERA?

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----------------Checksheet
Checksheet
----Checksheet / trend chart

Whether timelines for completion of each step for G8D clearly defined for tracking progress?

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Whether details of D0 updated in the centralized 'Concern Management System' (CMS) in

server?

-----

1
2
3
4
5
6

*Note - ERA is not the same as D3.

D1 - FORM TEAM
Based on the symptom, whether appropriate cross functional team is identified, including
suppliers as applicable?
Whether people responsible for implementation included in the team?
Whether all team members have been briefed about the symptom and other details as mentioned
in step - D0?
Whether team discipline is established in terms of meeting schedules, roles, timelines, review
and reporting etc?
Whether periodic team meetings are held with pre decided agenda to achieve the desired
deliverables of the improvement project?
Whether details of D1 updated in the centralized 'Concern Management System' (CMS) in
server?

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S.N.

GUIDELINES/ CHECKPOINTS

APPLICABLE TOOLS

EVALUATION
Yes/No/NA Comments from Evaluator

D2 - DEFINE THE PROBLEM (Problem Statement)

Whether the problem statement has been defined precisely in terms of :
a WHAT? (What is the 'nature' of problem & in which part?)

-----

b WHO? (Who is the person complaining? Write all the functions complaining about the problem.)

-----

WHERE? (a. Gegraphically the complaint is coming from. b. Where in the process flow and c.
Where in the component/ assembly?)
WHEN? (a. It first occurred? When all it has occurred? and when in product life cycle e.g. Kms,
d
days, hrs etc?
e HOW? (How did the person, identified in 'who' detect the problem?)
HOW BIG? (Quantify the problem in terms of a. Severity, b. Occurrence/ frequency, c. Value.
f
List down these 3 for every part number in 'what')
Whether photograph or skectch attached as appropriate for better clarity on the problem
2
statement?
Whether 'GOOD' & 'BAD' comparison is done through 'IS-IS NOT ANALYSIS' for the above 4W3
2H elements?
Whether actual place (GEMBA) visit made? And following details are checked?
4
A) Whether standards are present at suspected problem area?
B) Whether standards are known to the concerned persons and practiced?
Whether observations made during GEMBA is documented? And whether any conclusions
5
made?
Whether redefining the problem was needed based on the various observations (from past
6
data/Gemba observations)?
Whether details of D2 updated in the centralized 'Concern Management System' (CMS) in
7
server?
c

Process flow diagram, PFMEA

Traceability records, failure
data bank
PFMEA (Effects column)
Non conformity data and
stratification
----Is-Is not analysis
SOP, Control plan verification
Gemba orientation
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D3 - INTERIM ACTIONS (Containment and Immediate actions)

1a

1b
2a
2b
3
4
5
6

Whether suspect material is segreggated, quarantined and tagged in the entire supply chain as
applicable (Field, warehouse, FG, EOL, In process, receipt stores, supplier and all transits)?
Whether details w.r.t. qty., cut off nos., implementation dates etc are captured properly
subsequent to above containment action?
Note : This is required when verification/ validation is mentioned as 'yes'.
Whether specific immediate actions are clearliy determined which may include additional
inspections/ checks, additional operations etc?
Whether details w.r.t. qty., cut off nos., implementation dates etc are captured properly
subsequent to above immediate action?
Note : This is required when verification/ validation is mentioned as 'yes'.
Whether documented & clear Work Instructions are provided for the above containment and
immediate actions so that there is no ambiguity while implementation & execution?
Whether the above is communicated through document or mail to all concerned and affected
parties?
Whether adequate supporting data is available & included in G8D report w.r.t. Effectiveness &
implementation of Interim actions (both containment & immediate actions)?
Whether % effectiveness of each action clearly identified based on fact and team consensus?

Checksheet
----Checksheet
SOP
----Checksheet / trend chart
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S.N.

GUIDELINES/ CHECKPOINTS

APPLICABLE TOOLS

EVALUATION
Yes/No/NA Comments from Evaluator

7
8

Whether other similar products/ processes identified where the above interim actions are
required to be horizontally deployed? If applicable, whether a plan for same is in place?
Whether details of D3 updated in the centralized 'Concern Management System' (CMS) in
server?

Note : Further steps should not stop after the interim action is taken and found that the
problem is not reported.
D4 - ROOT CAUSE VALIDATION
Whether brainstroming is adequately done to determine probable causes? Whether team of
process experts involved during brainstorming?
Whether causes are adequately addressed - whether cause definition is clear?
Whether C&E diagram prepared and primary secondary causes are adequately written?
Whether toosl like 'Difference-Change analysis' and 'Change timeline' used for arriving at
probalble causes?
Are causes further stratified in terms of :
- Escape cause
- Occurrence cause
- System cause
a. Whether there is clear justification for coming from probable to root causes?
b. Whether past data of D0 & D3 (stratified data) is used for identifying probable causes?
Whether adequate data is collected for identified probable causes?

Whether data collected is analyzed systematically using various data based tools as applicable?

9
10
11

Whether good products are tested for absence of these causes?

Whether validation of each probable cause is by fact & data and not by opinion/ judgement?
Whether all backup sheets for validation of causes included in the G8D report?
Whether adequate supporting data is available & included in G8D report w.r.t. % contribution of
root causes?
Whether details of D4 updated in the centralized 'Concern Management System' (CMS) in
server?

1
2
3
4

12
13

2
3
4
5

D5 - SELECT PERMANENT CORRECTIVE ACTION

Whether brainstroming is adequately done to determine probable actions for each root cause?
Whether team of process experts involved during brainstorming?
Whether relevant tools for determining action for elimination of each root cause is used like:
- Tree diagram
- Decision making worksheet
- Solution selection matrix etc
Whether side effects of solutions are evaluated by team before action?
Whether final actions objectively determined with all necessary backup details?
Whether details of D5 updated in the centralized 'Concern Management System' (CMS) in
server?

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Brainstorming
Brainstorming
C&E diagram
Difference change analysis,
change timeline
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- Graphs/Charts/Stratification/
Stratified pareto/Control Charts/
Histogram/Scatter plots/DOE/
Data based decision
- Other validation tools as
applicable
-------------

Brainstorming
Tree diagram/ Decision making
worksheet/ Solution selection
matrix
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S.N.

GUIDELINES/ CHECKPOINTS

APPLICABLE TOOLS

EVALUATION
Yes/No/NA Comments from Evaluator

1
2
3
4
5
6
7
8
9
10
11
12
13

D6 - IMPLEMENT PERMANENT CORRECTIVE ACTION

Whether detailed action plan is made for each action including micro activities, responsibilities,
completion dates etc.?
Whether solutions are implemented on trail before making permanent change?
Whether full scale implementation plan is prepared & executed?
Whether there's a plan to systematically eliminate actions in D3 in a phased manner?
Note - This is required so that overall COPQ does not increase
Whether details w.r.t. qty., cut off nos., implementation dates etc are captured properly
subsequent to above actions?
Note : This is required when verification/ validation is mentioned as 'yes'.
Whether documented & clear Work Instructions are provided for the above actions so that there
is no ambiguity while implementation & execution?
Whether the above is communicated through document or mail to all concerned and affected
parties?
Whether adequate supporting data is available & included in G8D report w.r.t. Effectiveness &
implementation of permanent corrective actions?
Whether % effectiveness of each action clearly identified based on fact and team consensus?
Whether other similar products/ processes identified where the above permanent actions are
required to be horizontally deployed? If applicable, whether a plan for same is in place?
Whether before and after data is shown in the same graph/chart?
Whether any side effects noticed?
Whether details of D6 updated in the centralized 'Concern Management System' (CMS) in
server?

----------------Checksheet
SOP
----Checksheet / trend chart
--------Checksheet / trend chart
---------

D7 - PREVENT RECURRENCE & SYSTEM PROBLEMS

1
2
3
4
5
6
7

1
2
3
4
5

Whether standards for new methods are prepared? Revising the existing standards :Drawings,
specifications, DFMEA, DVP, PFD, PFMEA, Control Plan, SOP, Checklists etc?

PPAP documents & other

documents

Whether these actions adequately address system level root causes?

Whether concerned people are trained / made aware of new/modified standards?
Whether any verification audit is carried out to work as per the new or modified standards?
Whether results are monitored and whether result achieved is consistent?
Whether adequate supporting data is available & included in G8D report w.r.t. Effectiveness &
implementation of system level corrective actions?
Whether details of D7 updated in the centralized 'Concern Management System' (CMS) in
server?

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D8 - TEAM AND INDIVIDUAL RECOGNITION (CONCLUSION)

Whether lessons learnt is documented and discussed with team?
Whether opportunity for horizontal deployment is identified? And plan for same is worked out?
Whether complete dossier for G8D is documented for future references and usage and shared
with other members in the organization so that learnings are effectively utilized?
Whether tangible & intangible benefits are calculated & included in the overall report?
Whether details of D8 updated in the centralized 'Concern Management System' (CMS) in
server?

Checksheet / trend chart

-----

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Date opened:

D0 - Problem Defination
Last updated on:

Product/Process Information:

Organisation/ Supplier Information:

D0 Symptom(s):

Radiator failures in warranty

D0 Emergency Response Actions (ERA) - if applicable:

Details of action -

% Effective

Details of implementation Location

(as applicable)

No. of
vehicles

Cut off no.

(if applicable)

Field
SPD
Yard
Plant (Post CAI)
Others

Verified effectiveness (Y/N)?:

Details of verification of effectiveness :

ERA removed (Y/N)?:

ERA removed on :
Details of ERA removal:
Service action required (Y/N)?:
Details of service action:

*Note - ERA is not the same as D3.

Remarks

Date Implemented

Team meeting frequency :

Last meeting held on :

D1 - Team Declaration - format

S.N.

Member

Title

Location

Phone

Date opened:
Last updated on:

m meeting frequency :
meeting held on :
e-mail