Root Cause Analysis and CAPA using 8-D Problem Solving Method 2019

Topics

• Ford’s Team Oriented Problem Solving, 8 Disciplines (8D) method (TOPS-8D), AIAG’s similar Effective Problem Solving process, and Toyota’s A3 process use similar structured plan-do-check-act (PDCA) approaches to identify and then remove a problem’s root cause
• ISO 9001:2015 and IATF 16949 require CAPA, and CAPA plays a key role in deployment of ISO 9001 clause 6.1, Actions to address risks and opportunities. Risks and opportunities, however, include not only the traditional ones related to poor quality but also the Toyota production system’s other six wastes. These also are removable by the CAPA process
• Error cause removal (ECR), or the hiyari hatto ("experience of almost accident situation") empowers workers and other interested parties to initiate CAPA for safety and quality risks, and also waste or muda. A formal CAPA process such as 8D is not required if the process owner can easily resolve the problem on the shop floor
• Standardization of the solution makes it permanent, and best practice deployment extends it to related activities. The solution also becomes part of a lessons learned data base to support organizational knowledge
• The superiority of engineering controls, poka-yoke, error proofing, or what was known as "Can’t rather than don’t" (as in "Can’t do it wrong" rather than an admonition "Don’t do it wrong") at the Ford Motor Company, over administrative controls that rely on worker vigilance, cannot be overemphasized

Who should Attend

• Quality Control Departments
• Quality Assurance Departments
• Manufacturing Departments
• Research and Development Departments
• Operations Departments
• Engineering Departments
• Everybody with CAPA responsibilities under ISO 9001:2015 or IATF 16949
• Production Departments