8D Approach to Problem Solving

Description

8D Approach to Problem Solving: 2-day classroom workshop

8D (Eight Disciplines) is a structured, team-based method for solving product and process problems. A cross-functional team finds the root cause, puts permanent corrective action in place and stops the problem coming back. The method was developed by Ford Motor Company as Team Oriented Problem Solving and is widely asked for by automotive and manufacturing customers.

In this 2-day practical workshop, participants work through each discipline step by step, learn the problem-solving tools that 8D uses, and apply them to a real problem during the class.

Course facts

Duration	2 days, 9.00 am to 5.00 pm
Format	Classroom
Fee	RM2,198 per participant
Class size	Up to 20 participants
HRD Corp	Not currently HRD Corp claimable
2026 public session	28 to 29 December 2026 (dates may change if minimum numbers are not met)

The eight disciplines

1. D1 Form the team: a small group with the knowledge, time, authority and skill to solve the problem, led by a team leader.
2. D2 Describe the problem: state the internal or external customer problem in measurable terms.
3. D3 Contain the problem: put interim actions in place that protect the customer until the permanent fix is in, and verify them with data.
4. D4 Find and verify the root cause: list every potential cause, test each against the problem description and data, and confirm the root cause and its escape point.
5. D5 Choose and verify the permanent corrective action: confirm the action resolves the problem for the customer without side effects.
6. D6 Implement and validate the permanent corrective action: put ongoing controls in place and monitor the long-term effect.
7. D7 Prevent recurrence: update specifications, training, work flow, practices and procedures so this and similar problems do not return.
8. D8 Recognise the team: close the 8D, share what was learned and recognise the team’s effort.

The workshop also covers D0, preparing for the 8D: the problem symptom, quantifying it and deciding whether an 8D is needed.

What you will learn

• The 8-step systematic problem-solving process and why a team-based approach works better than solving alone
• The tools used at each step, applied to a real problem with feedback from the trainer
• Why a standardised approach to problem solving matters, especially when meeting customer requirements

Course outline

Section 1: 8D overview. Team problem-solving principles; the 8-step process; cross-functional team structure; inductive and deductive problem solving; change-induced and never-achieved problems.

Section 2: Analytical tools used in 8D. Brainstorming rules; Ishikawa (fishbone) and affinity diagrams; control charts; how 8D relates to FMEA; why-why and 3×5 Why techniques; error proofing (poka yoke); incident mapping, interfaces and noise factors.

Section 3: The 8D process, step by step. D0 preparation and criteria for continuing; D1 team roles, preparation and core team; D2 problem description with Is / Is Not, affinity diagram and incident map; D3 interim containment action; D4 root cause analysis, human factors, comparative analysis, root cause verification and escape point; D5 selecting and verifying permanent corrective action, including error proofing; D6 implementation with a Plan-Do-Study-Act plan, change management, stakeholders, validation criteria and sample size; D7 prevention through processes, procedures and lessons learned; D8 closure and document archive.

Who should attend

Managers, engineers, supervisors and technicians, including quality and logistics staff.

How the course is taught

A team-focused workshop combining facilitation, theory and short lectures, discussion, and hands-on work on a real problem during the two days.