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Introduction of Ford 8D

-Team Oriented Problem Solving Methodology-

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Outline

8 Disciplines 8 D Form Ford 8D Example

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Ford 8D Disciplines

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8D Form

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the problem warrant/require an 8D? If so comment why and proceed.

Prepare for Problem Solving - Does

Is an Emergency Response Action Needed? (If needed document actions in Action Item Table)

Team Assembled - Establish a small group

Team Goals: Team Objectives:

1

of people with the process/product knowledge, allocated time, authority and skill in the required technical disciplines to solve the problem and implement corrective actions.

Departme nt

Name (Team Leader First)

Skills

Responsibility

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2 A

the starting point for solving the problem or nonconformance issue. Need to have "correct" problem description to identify causes. Need to use terms that are understood by all.

Problem Description - Provides

Sketch of Problem

Part Number(s):

Customer(s):

List all of the data and documents that might help you to define the problem more exactly?

Is there an action plan to collect additional information?

Prepare Process Flow Diagram for problem. (Attach to PSW)

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2B

Who

IS

Who is affected by the problem? Who first observed the problem? (internal/external) To whom was the problem reported? What type of problem is it? What has the problem? What is happening? Do we have physical evidence of the problem in our possession? Why is this a problem?

IS NOT

Who is not affected by the problem? Who did not find the problem?

What does not have the problem? What could be happening but is not? What could be the problem but is not? Why is it not a problem?

What

Why

Is the process where the problem occurred stable? Where was the problem observed? Where could the problem be located but is not? Where else could the problem be located but is not? When could the problem have been noticed but was not?

Where

Where does the problem occur? When was the problem first noticed?

When How Much/ Many How Often

When has it been noticed since? Quantity of problem? How Much is the problem causing in dollars, people, & Time? What is the trend (continuous, random, cyclical)? Has the problem occurred previously? (If so attach previous PSWs & CIFs) How many could have the problem but don't? How big could the problem be but is not? What could the trend be but is not?

Problem Description - Combine the relevant information, this will be your Problem Description

2C

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"fix" until permanent correction is in place. (Note: Validate that the action taken works). Document Actions in the Action Item Table

Interim Containment Actions - Temporary actions to contain the problem and

3

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Diagnose Root Cause

4A 4A

People

­ Analyze for "Root Cause" of the problem. Identify and verify the Escape Point. Brainstorm the possible causes of the problem (attach)

Cause and Effect Diagram (Attach copy of complete diagram(s) as appropriate)

How made?

Materials/Info Machine

Problem (effect)

Why did it get out?

People Materials/Info Machine

Method

Environment

Measurement

Method Environment Measurement

Note on Diagram(s) circle the most likely contributors (3 max) from each side.

4B

5 ­ Why Analysis

Ask ­ Why did this happen? Ask ­ Why did this happen? Ask ­ Why did this happen? Ask ­ Why did this happen? Ask ­ Why did this happen?

4C

Action Plan - Based on the team's discussions.

Begin to complete the Root Cause Action Plan to verify and validate the root causes and test the escape point. Document this on the Action Item Table.

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5

Solutions determined to be the best of all the alternatives. Document and verify the Permanent Corrective Action (PCA) in the Action Item Table.

Identify Solutions ­ Solutions that address and correct the root cause.

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Validation - Implement and validate to ensure that corrective action does "what it is

supposed to do." Detect any undesirable side effects. Document this on the Action Item Table. Return to root cause analysis, if necessary.

6

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7

Prevention (Design / Information Systems Review) - Determine

what improvements in systems and processes would prevent problem from recurring. Ensure that corrective action remains in place and successful.

7A

Process / Item

Address Similar Systems - List similar systems with the potential for the

same defect. Issue a CIF for items identified. Accountability

CIF #

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7B

Document

Review the following documents / systems.

Completion Date Accountability Planned Actual

Management System Manual Manufacturing Work Instructions Inspection Work Instructions Flow Charts Control Plans Design FMEA Process FMEA Gauges/MMD/IMTE PPAP Engineering Change Approval Manufacturing Forms Inspection Forms

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Congratulate Your Team

- Use all forms of employee recognition and document as necessary.

8

Celebrate successful conclusion of the problem solving effort. Formally disengage the team and return to normal duties.

Was the PSW Effective?

Yes/No

Signature/Title

Date

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Action Item Table

Actions

Action # Fault / Item Containment/ Corrective Action Verify How Verified

Implement and Verify Actions

Action Accountability Planned Actual Status

Registered problem and Short Term Corrective Action in place in house.

Long Term Corrective Action developed but not implemented.

Long Term Corrective Action implemented.Monitoring/evaluating effectiveness.

Long Term Corrective Action confirmed effective. Problem closed.

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-

8D Example TSMC Etch Module

DØ : Prepare for the 8D Process D1 : Establish The Team

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D2 : Describe The Problem

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D2 : Describe The Problem

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D2 : Describe The Problem

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D3 : Develop the Interim Containment Action and Verification

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D3 : Develop the Interim Containment Action and Verification

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D4 : Define and Verify Root Cause and Escape Point

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D6 : Implement and Validate Permanent Corrective Actions

D4 : Define and Verify Root Cause and Escape Point

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D4 : Define and Verify Root Cause and Escape Point

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D4 : Define and Verify Root Cause and Escape Point

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D5 : Choose and Verify Permanent Corrective Actions for Root Cause and Escape Point

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D6 : Implement and Validate Permanent Corrective Actions

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D6 : Implement and Validate Permanent Corrective Actions

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D8 : Recognize Team and Individual Contributions

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Thank You

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