ForgeShiftCompass
QualityPractice B3

8D Problem Solving

8D is a structured 8-step team problem-solving method for significant quality escapes — from containment, through root cause, to permanent corrective action and recurrence prevention.

  • Assessment4 questions
  • Templates1
  • Root causeISHIKAWA-6M

What world-class looks like

All significant quality escapes and recurring defects are investigated using 8D; root cause is verified, corrective actions implemented, and recurrence prevented.

How mature is your operation?

These are the questions Compass asks for this practice, and the levels it scores you against.

Problem description (D2)

Structured what / where / when / how-many problem statement.

When a significant quality problem occurs, how formally is the problem described before investigation starts?

Level 1 → 5World class at level 4

  1. We jump straight to fixing — no formal description
  2. Verbal description shared with the team
  3. Written problem statement, sometimes
  4. Structured problem statement: what, where, when, how manyWorld class
  5. Is/Is-Not analysis completed before root cause work begins

Interim containment (D3)

Stop the bleeding before investigating root cause.

When a defect escapes or is discovered, how quickly do you contain the risk?

Level 1 → 5World class at level 4

  1. No formal containment — we investigate while product flows
  2. Informal sorting or hold of suspect stock
  3. Written containment action with responsible person
  4. Formal containment plan with verification that defective product is stoppedWorld class
  5. Automated containment triggered by SPC out-of-control signal or ANDON

Root cause analysis (D4)

5-Why, Ishikawa, or data-driven root cause verification.

What method do you use to find the root cause of quality problems?

Level 1 → 5World class at level 4

  1. We rely on gut feel or experience
  2. Informal discussion — we agree on a likely cause
  3. 5-Why analysis, sometimes documented
  4. Structured 5-Why or Ishikawa diagram, verified against dataWorld class
  5. Root cause verified by experiment or data before corrective action

Prevent recurrence (D7)

Systemic change, not just fix-it-once.

How do you ensure a quality problem cannot recur after it has been fixed?

Level 1 → 5World class at level 4

  1. We fix the immediate issue only
  2. Informal communication to operators about what to watch for
  3. Update work instructions or inspection criteria
  4. Systemic change: update PFMEA, control plan, and similar processesWorld class
  5. Lesson learned formally shared across all similar processes and sites

Where to start

  • 8D digital workflow

    Quality · L1→L2 · Low complexityCloses · Root cause analysis (D4)
Root-cause methodISHIKAWA-6M

Next steps

Scoring your operation against 8D Problem Solving takes a few minutes and needs no account.

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