Ford Focused 8D Problem solving method

Course Overview:

After identifying the root cause of any problem. Effective problem solving method is chosen. To rectify the problem, and build the right improvement and sustainment plan. One of the most effective methods is the 8D approach created by Ford. Through this course the participants will be able to understand the elements of the 8D process.


  • Ishikawa (fishbone)
  • Affinity diagrams
  • Is/Is/Not
  • Process flow
  • Comparative analysis.

The course will display several case studies. Present relevant exercises. Provide the exact process flow of 8D approach, in an interactive environment. With a cross functional team. The participants will learn how to build a corrective and control plans. And lead the teams in long term sustainment.

Who Can Enroll:

  • Process owners
  • Supervisors
  • Team leader.

Course Features:

  • Process improvement resources, lean six sigma resources.
  • Material and templates included in course cost.
  • To achieve certification, participants shall achieve 80% in CHOOLS exam for course only.
  • Course could be customized for organization requirements including company LOGO.

Learning Outcome:

  • Understand and apply 8D process.
  • Link 8D to other problem solving methods such as FMEA and product development process such as advanced product quality planning (APQP)
  • Understand and apply root cause analysis mechanisms.
  • Set up Cross functional teams and lead team in 8D implementation.
  • Build the effective improvement and sustainment plan (control plans).
  • Create and manage an 8D library as a reference for future use.
  • Understand and apply the various related tools: 5whys, Fishbone, affinity, Is/Is Not, SPC, and Poka Yoke (mistake proofing).

Why Choose Chools?

Access to:

• Top 100,000 Ebooks.
• 250,000 Management slides and presentations.
• 1 million excel templates.
• 60,000 business documents.

• 15,000 top books in abstract forms.
• 40,000 audio podcast.
• 550 audio library books.
• 50,000 video libraries.

• 1500 training courses.
• 2.6 million Journals and articles.
• 137 Lean Six Sigma toolkit.
• Leadership assessments.
• Quiz, Exam prep, Q&As, Case-studies.

Course Outline:

Section 1 – 8D Overview

  • Team Problem Solving Principles
  • Process Description (9 Step Process)
  • Team Structure (Cross Functional Team)
  • Inductive vs. Deductive Problem Solving
  • Change-Induced Problems
  • Never-Achieved Problems

Section 2 – Review of Analytical Tools in 8D

  • Brainstorming Rules
  • Ishakawa / Fishbone
  • Affinity Diagram
  • Control Chart
  • Relationship between 8D andFMEA
  • 5 Why (3-Legged Approach)
  • Interfaces and Noise Factors
  • Error Proofing

Section 3 – 8D Process Step by Step

  • D0 – Prepare (Plan) for the 8D
    • Problem Symptom
    • Quantified Symptom
    • Criteria for 8D Continuance
  • D1 – Form the Team
    • Roles and Responsibilities
    • Team Preparation
    • Agenda and Rules
    • Core Team and SMEs
  • D2 – Problem Description
    • Repeated Why
    • Affinity Diagram
    • Is / Is Not
    • Workshop on Problem Statements and Brainstorming
    • Workshop on Problem Description Development
  • D3 – Interim Containment Action (ICA)
  • D4 – Root Cause Analysis (RCA) and Escape Point
    • Human Factors(Operator Error)
    • Comparative Analysis
    • Root Cause Theories
    • Root Cause Verification
    • Escape Point
    • Workshop on Root Cause Theories
  • D5 – Permanent Corrective Action (PCA)
    • Methods for Selecting PCA
    • Error Proofing
    • Verification of PCA
  • D6 – Implementation and Validation of PCA
    • Plan, Do, Study, Act(PDSA) Implementation Plan
    • Change Management
    • Stakeholders
    • Validation Criteria and Sample Size
  • D7 – Prevention Action
    • Processes and Procedures
    • Lessons Learned
  • D8 – Closure and Congratulate the Team

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