Research On Applying 8 Disciplines Problem Solving Process In Automotive Parts Quality Improvement

Traditionally Eight Steps Solution(Ford-8D)was used in arguments between automotive suppliers and manufacturers,and sometimes extended to the third or fourth level suppliers.Ford-8D mainly focuses on the improvements on one special problem for one manufacture/supplier or one specific process.Things changed with the specialization and refinement of modern manufacturing enterprises,more processes and more suppliers may involve in one problem which makes the situation much more complicated than before.To avoid products with the same category defects from different reasons happening repeatedly,more understanding and cooperation between corresponding processes and supplies are desperately required.This is the main contents of the research.The major improvements the study has made includes the following aspects:1,D4 will be divided to 5 sub-steps,the improvements make it much easier to solve problems among several manufacturing processes or different suppliers,thus cooperation is required.As an illustration in one argument may involve with two suppliers,each supplier will have its independent 8D group with team leader responsible for its own company,while these two 8D groups will communicate with each other for issues that may happen.The key improvement is in step D4 for the reason tracking,in case of losing one of the possible reasons leading to the argument,D4 will be divided to five sub-steps: defects analyzing,process tracking,possible reason digging,important factor investigating,and data recording.The quality control for each step is also defined carefully.The efficiency and quality of solving problems from product defects can be dramatically improved with the refinement and standardization of the process of analysis together with the cooperation of two 8D groups.2,With regards to the permanent improvement measures in D6 step,we proposed refinement concept based on process procedure.Consider all permanent action on important factors(even it is not the root cause of this happening).By using techniques such as DOE,we conducted experiment on major influencing factors to determine appropriate control parameters.We used PFEMA to reanalyze factors such as failure modes,occurrence frequency,and detection method.By identifying process attributes,we incorporate measures into process control to prevent same product defects from happening.In D7 of failure prevent,we suggest to emulate those attributes from the PFEMA and use them in the same step of different products,to avoid similar defects occurring in other products.With those approaches,companies can accumulate experience and knowledge to form standardized control measures.3,In the aforementioned real case with corporation S,we have demonstrated that it is workable to have multiple processes,multiple suppliers coordinating simultaneously.Detailed procedure helps on-site execution and standard work instruction.The process-based permanent improvement measures can also help mitigate similar defect happen again.In the case,twp supplier 8D steps finished before customer requirement time,less than normal at least half of the time,and consider overall permanent action to eliminate the similar problem happened again.