The 8D (Eight Disciplines) is a systematic approach to solving complex problems, especially effective for recurring or critical non-conformities in industrial environments. Originally developed by Ford, 8D is now a global reference for structured corrective actions, with traceability and organizational learning.
The 8D goes beyond just correcting the problem: it aims to eliminate the root cause, prevent recurrences, and improve the process.
🧩 The 8 Disciplines of 8D
| Step | Name | Objective |
|---|---|---|
| D1 | Form team | Gather people with knowledge of the process and the problem |
| D2 | Describe the problem | Clearly define the defect with measurable data (product, location, date) |
| D3 | Containment action | Isolate the problem, protect the customer, and avoid immediate impact |
| D4 | Identify root cause | Use tools like 5 Whys, Ishikawa, data analysis |
| D5 | Permanent corrective action | Develop a definitive solution based on the identified cause |
| D6 | Implement and validate solution | Verify effectiveness with tests and monitoring |
| D7 | Prevent recurrence | Update documentation, training, processes, procedures |
| D8 | Recognize the team | Record and disseminate the success of the resolution and generated learning |
🔧 Practical Application of 8D in Testing Systems
AJOLLY Testing applies the 8D methodology to solve recurring test failures, measurement variations, performance issues, and field non-conformities.
🛠️ Integration with Test Data
- Automatic logging of repetitive failures (Top Failures) via TestStand or LabVIEW
- Association with serial number, operator, station, date, and firmware
- Generation of Pareto and Ishikawa charts directly from the test database
🧠 Technical Tools for D4 (Root Cause)
- 5 Whys based on documented events
- Analysis of communication logs, measurement curves, CPK/FPY statistics
- Cross-inspection between tests, DUT, jigs, and operators
📈 Validation and Traceability of Actions
- Corrective and Preventive Actions (CAPA) reports with status and dates
- Digital checklist for technical validation of D6
- Effectiveness tracking by new KPIs after D7 (failure reduction, response time)
📊 Benefits of Using 8D with AJOLLY Testing
- Definitive reduction of critical and chronic failures
- Structured documentation of each resolution
- Technical and managerial traceability (via MES, SCADA, or dashboards)
- Culture of continuous improvement based on data and technical collaboration
With AJOLLY Testing, the 8D methodology is applied with technical rigor and complete digital support, transforming each problem into an opportunity for learning and lasting improvement.