UNIVERSITY OF PITESTI SCIENTIFIC BULLETIN
Faculty of Mechanics and Technology AUTOMOTIVE series, year XXV, no. 29
Application of 8d methodology - an effective problem solving
tool in automotive industry
Cristina – Florena BANICA, Nadia BELU*
University of Pitesti, Pitesti, Romania
*Corresponding author e-mail: nadia.belu@upit.ro
Article history
Received 20.06.2019
Accepted 15.08.2019
DOI https://doi.org/10.26825/bup.ar.2019.005
Abstract: Quality plays an important role in an organization from automotive industry to
become more efficient and effective in the global market. In this sector there are many
requirements to problem solving process using standardized methodologies, according to
international standards. 8D methodology has become very popular among manufacturers
because it is effective to use. The aim of this paper is to apply the 8D methodology and to
analyze its effectiveness. In order to apply the 8D methodology and to analyze its effectiveness
a case study was conducted in a company from automotive industry. The results can be used
by the management in continuous improvement as additional motivation for more effective
use.
Keywords: 8D, QRQC methodologies, problem solving, quality improvement
1. Introduction
The automotive industry is one of the most important sectors of the global economy. Improvement in
quality of product and process is necessary for any company from this sector in order to survive and to
grow in competitive market. For this, problem solving techniques are required by the quality
management in the automotive industry. Regarding quality management, problem solving is fostered
by the Measurement Systems Analysis work group [1], [2] and the standard IATF 16949:2016 of
International Automotive Task Force [3], [4], [5] for automotive industry. The goal of this QMS
standard is the development of a quality management system that provides for continual improvement,
emphasizing defect prevention and the reduction of variation and waste in the supply chain. According
this standard, the organization shall have a documented process for problem solving including: root
cause analysis, methodology used, analysis and results. One of the methods used is 8D methodology
based on Quick Response Quality Control (QRQC) tool. The 8D method (also called G8D, Global 8D,
TOPS 8D) is one of the most widely used problem-solving tools related to nonconformities
reoccurrence prevention in the manufacturing process, commonly used for complaints management in
automotive industry. It consist of 8-steps to be followed by quality improvement team for problem
solving as well as for product and process improvement [6]. QRQC is described as a quick and
comprehensive problem-solving process for the industrial and services sectors that ensures problems
do not reoccur while at the same time establishing dynamics of continuous improvement and
modifying management culture. This paper presents the 8D methodology through case study for
improving of quality in the automotive industry for powder painting processes.
2. 8d methodology
The 8D methodology is effective in developing proper actions in order to eliminate root causes and in
implementing the permanent corrective actions to eliminate them. It also contributes to explore the
system of control that allowed the escape of the problem [7], [8], [9]. The 8D methodology involves
teams working together in order to solve quality problems, using a structured 8 phases, table 1 [9].
QRQC is a quality tool support of the 8D methodology. The basis of QRQC is the quick answer to a
quality / manufacturing issue no matter if it's an external / internal customer or a supplier.
Table 1. Phases of 8D Methodology
Phase of the
No. 8D Description
methodology
1 Problem To identify the problem, the 8D team tries to acquire more information as possible from the
description customer, which constitutes the first analysis performed in the problem-solving process. The
location and nature of problem must be given along its effects. Another important information
is whether the problem included is intermittent or whether it could happen on similar products
or processes. While depicting the problem, the 5W (Who, What, Where, When, Why) And 2h
(How, How Many/Much) method should be used, where the accompanying inquiries must be
addressed completely and efficiently and WHY for each question. The responses to these
inquiries help us clarify the background and connections.
2 Reference to This phase is done with the purpose to detect other products with the same nonconformity risk.
similar The subsequent aspects must be taken into consideration: the list of the detected problems, the
products place of their detection, the technological process in question, what other parts are realised in
the same process, whether here is also a nonconformity risk in what they are concerned, where
these parts are used.
3 The first In this step identification of genuine cause and determination of restorative measures aimed to
analysis solve the problem permanently. To obtain root cause, all the causes which are found wrong are
wiped out. Both the manufacturing process and the control process are taken into account. The
point where the problem has escaped the control system (escape point) must be sought for and
detected, as well as the moment when it could have been detected.
4 Immediate Measurements are carried by two means, it is carried out by
action plans • means of control devices (digital data and outputs are associated to computers)
• means is carried out by using statistical methods: statistical Process Control, Process
Capability (cp), Process Capability index (Cpk), histograms, and Pareto diagrams.
5 Final This phase is carried out with the purpose of obtaining a real and complete of the situation in
analysis order to find the root causes and to decide the optimum actions required for the treatment of the
causes. This phase aims at finding the causes, not the solutions. Final analysis implies a
detailed analysis of the data. For this purpose, multidisciplinary team work is used; such teams
go on the respective site in order to understand the problem. It must be noted that most of the
complex problems usually have more than one root cause that interact with each other.
The validity of these causes should be verified because it is essential to treat the real causes.
6 Final action Establishing an implementation plan for permanent corrective actions. Permanent actions are
plans analysed and applied in order to prevent the recurrence of the problem permanently. The final
elimination action must be focused on the real main root causes (phase 5) and on the escape
point (phase 3). Thus the aim is to solve both the root causes of the problem, as well as the root
causes of the failure to detect the problem. In order to prevent the recurrence of the problem, a
number of actions are applied: updating procedures, training the personnel.
7 Confirmation Phase 7 of the 8D method is very important due to the fact that it allows for the closing of the
of the action action plans. The effectiveness of the final action plans is checked. It is a key stage meant to
plans avoid the recurrence of the quality problem.
The Supplier Quality Service will require evidence of the effectiveness of the action plans and,
in order to be able to validate the 8D, may also perform an audit if it finds that the effectiveness
of such actions is not trustworthy. So long as the effectiveness of the actions is not proven, the
supplier should make sure that it supplies 100% good parts by carrying out checks.
The Supplier Quality Service will be notified in what the results of such checks are concerned.
8 Preventing a In this step the 8D team analyse whether the corrective action executed would avoid or enhance
recurrence of the quality of similar products and processes.
the problem
2
3. Case study
In our paper, we have focused on the use of 8D methodology to solve the various problems
encountered in the production of automotive components. In our case it was a problem that occurred
during powder painting processes, Figure 1. The problem was identified in the Quality Wall by an
operator. Powder painting is the application of solid powder to create industrial coatings.
The powder is applied by an electrostatic process to a substrate, usually metal, and acquires excellent
properties when the particles are heated and polymerise on the substrate. This method is widely used
to protect surfaces and ensure a pristine finish that cannot be achieved with regular paints.
Date: 30.09.2019
Part name : Bar HJD PH3 ROOF BAR
Part number : 112240
Impurities and cavities on the surface of the bars
Quantity: 229 parts
Nonconforming part Conforming part
Figure 1. Nonconforming painted parts
This problem was solved by using 8D and QRQC methods. The stages of the methodologies are
shown below in the table 2 - 9.
Table 2. Problem description
Reference Number: 112240 Issued by: Validated by :
Parts name: Bar HJD PH3 ROOF BAR Function Function
Date Date: 30.09.2019
30.09.2019
1. Details of the problem Date:
Report N°: 6102-3339 Affected quantity: 229
Description: Impurities and cavities on the surface of the bars
Why is it a problem? Visual problem.
Who detected the problem? Customer
Who generated the problem? Supplier
How was the problem detected? Customer production line visual control
When did the problem occur? 30.09.19
When the part has been produced? 18.09.19
How many? 128 Nonconforming bars and 229 Nonconforming painted bars
Yes No
Recurrence √
3
Table 3. Reference to similar products
2. Other concerned similar products?
Can this defect appear on other similar parts?
Yes No Comments / Results
Other pieces √
Products same family √
Left / Right √
Symmetric product √
Front / Back √
Others √
Table 4. The first analysis
3. First analysis
At this step we used QRQC methodology, a tool for quick resolution no repletion the problems. It uses tools as
Ishikawa diagram and 5 Why.
5W1H method allows the problem to be broken down and determine a root cause.
Description of the problem Results
What is the problem? Impurities and cavities on the surface of the bars
Who detected the problem? Operator
Where was the problem detected? Quality Wall
When was the problem created? 30.09.2019
How many? 229 parts
Why is it a problem? The client's requirements are not respected
The cause of this problem will be further investigated using the Ishikawa diagram, figure 2 (which is also named Fishbone).
That constitutes a significant point in the topic of methods for problem solution is actuating as a key tool to solve assembly
and maintenance troubles in the automotive and transport sectors. It is used to identify possible causes of a specific
problem.
Figure 2. Fishbone for impurities and cavities on the bars surface
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5 Why it is a simple approach to explore the causes until the root cause is reached.
Why? Why? Why?
Parts have small scratches, which The raw material had scratches, which Operators were not enough
can be seen after painting process. stay even after the surface treatment informed about the surface
processes. The parts with small surface criteria.
failures were not detected.
The non-detection actions for the pallet support product in the table 2 are identified below.
Non-detection actions Department
Elaboration of the pickling verification method Methods
Instruction sheet for checking the bars support after pickling Methods
Identification of the defect in critical board Quality
Instruction sheet for checking rust on the bars support Methods
Figure 3. Failures evolution
Before the analysis, the average of the failures was 4.6, figure3, after the analysis the results obtained will be analyzed.
Table 5 Immediate action plans
4. Immediate action plan
Which are the actions began to prevent the delivery of not corresponding products to customer?
Actions Quantity Quantity
conform Not conform
During the manufacture process 0 0
Current stock 0 0
Stocking in Shop 0 0
Spare pieces 0 0
Others 0 0
How are OK products identified?
Labeled: Checked 100%
Expedition date / Remarks
Table 6 Final analysis
5. Final analysis End date of analysis 20.10.2019
Indicate the real causes on the whole Process:
* Man, Material, Machine, Methods
* Who, Where, When, Why, How
* Changement de fabrication. Processus de Retouches
* Maintenance
Causes: Responsibility Department
Nonconforming self-control D.G. Production
New products, undisclosed by operators P.R. Production
The hanging of parts on the carriers is nonconforming P.R. Production
The available conditioning does not protect the parts against
C.A. Quality
scratching due to contact between them
The instruction sheet about the parts hanging is missing P.R. Production
5
Table 7 Final action plans
6. Definitive action plans W49
Actions Service / Date
Responsibility
Realization of a Quality Alert Quality W48
Sorting in the customer plant Production W48
Sorting in the logistics platform Production W48
Sorting in lorries being loaded or on the road Production W48
Training of the operators about the failures and the company control criteria Production W48
Visual control and marking has been implemented after bending process to
Production W46
increase awareness on surface failures at polishing operation
Training of the operators concerning the parts hanging on the carriers Production W48
Visual control has been improved after painting process by adding
Production W48
additional visual control
Defining, with the customer, the conditionings to protect the parts during
Quality W49
transportation
100% Control and labeling of the first three deliveries Production W48
Table 8 Confirmation of the action plans
7. Action Plans Confirmation Validation date 20.10.2019
The begun actions were confirmed like effectives? Yes No
√
Comment?
8D audit performed to demonstrate if the actions are sustainable and effective.
Table 9 Preventing a recurrence of the problem
8. Preventing a recurrence of the problem Closing Date:
After the update of the actions, the following subjects require one updated?
Yes Responsibility Date
All actions validated and put in place √ Production 04.11.2019
Product FMEA and/or Process updated √ Quality 04.11.2019
Control plan updated √ Quality 04.11.2019
Update procedures √ Production 04.11.2019
Instructions (control monitoring plans) √ Production 04.11.2019
Specifications adapted (only in project) √ n/a
Product / process design guide updated (only in project) √ n/a
Lessons learned created and shared √ 04.11.2019
The audit performed by Quality and manufacturing at the √
maintenance operation level 1
Each month, an information session on customer complaints and √
internal complaints will be organized within the welding workshop
The final stage of the 8D report aims to summarize all the experience and knowledge of the team, as
well as the documentation used to prepare the 8D report. After taking the permanent corrective and
preventive actions and closing the 8D activity through quality planning, the average of the failures
reduces to 4.6 from 2.4.
4. Conclusions
The 8D methodology used in this paper is an excellent tool for solving the problem as well as for
preventing defects from reoccurring. It is practical and simple sheet, which use isn´t allwasy easy.
Appear as one of the basic problem solving methodology, 8D offers an essential solution from
identifying the root cause until the implementation of preventive action. When solving a complaint,
8D reports are always demanded form suppliers. A future work can be suggested for other production
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cases in which the 8D methodology to be used like a support for Failure Mode & Effect Analysis or
Quality Assurance Matrix - tools for quality improvement in the automotive industry.
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