1. 8 DISCIPLINE METHDOLOGY

2.  To ensure a systematic and orderly way of solution
to the problems, and their easy recorded is
recommended widely known in the automobile
market.
Advantages:
 1. Easy and logically method, clearly shows Next
steps of problem solution.
 2. Often this is a required method of documenting
the correction action for the customer.
 3. An excellent way of reporting nonconformance’s
to suppliers and their corrective actions.

3.  D1 – Team Building
 D2 – Problem Information
 D3 – Interim Action
 D4 – Root Cause Analysis
 D5 – Chosen Permanent Corrective Action
 D6 – Implement Corrective Action
 D7 – Preventive Action
 D8 - Submit 8 D Report and Congratulate the
Team.

4.  Champion – By default Plant Head.
 Team Leader- Process Head
 Facilitator – Person who is having knowledge of
QMS.
 Team Member – Asst. Manager, Shift Supervisor,
QA Inspector, Operator.
 If required Maintenance and Purchase person can
be include as team member.

5. - Defect
- Defective
- Defective phenomenon
Don’t work on assumptions.
Deviation from requirement.
What type of defect
Frequency of defect

6.  Inventory of WIP material
 Stock Checking (In house / Customer end)
 Inspection Frequency
 Inspection Method

7. Find the root cause by any of following
method
 Why – Why Analysis.
 Fish Bone Diagram.
 Simulation Test.
 Brainstorming.
 IS – IS Analysis.
 Design of Experiment.

8.  Root cause for escape.
 Occurrence – Method, Process step.
 System failure.
 DOE – Set the process from start to end.
Increase inspection means, not sure about process.
Automatic data capture through wireless costs 35
to 40K.

9. Action to eliminate
 Occurrence of Defect.
 Escape
 System failure
Decide the action and check its effectiveness.

10.  Arrange training if required.
 Monitoring of Implementation.
 Data collection for verification.

11. Decide preventive action to avoid non conformance
in advance.
Standardization and horizontal deployment
Effectiveness Similar Up gradation
process/product of QMS Doc.

12. Take a movement to look at this problem. Why
did it happen in the first place? What lesson
can be learnt? What changes need to be made
to ensure that this and similar problem never
happen again. Note down same specific
improvement that need to be made in area such
as system, procedure, machinery, maintenance,
people and training.

13.  Customer complaint communication.
 Control plan, FMEA, Process Flow Diagram
 Work Instruction.
 Specification chart.
 Process Audit Check list.

14.  Collect all documents and make a file.
 Report all activities you have done from D1 to
D7 for particular complaint.
 Submit report to Champion.
CONGRATULATE THE TEAM FOR
SUCCESSFULLY CLOSING OF 8 D REPORT.