GlossaryKind of term: Manufacturing term8D report
What is an 8D report?
An 8D report documents how a quality problem is handled in eight steps, from containment through root cause to a permanent corrective action.
An 8D report documents a structured approach to a problem in eight disciplines. The method became widespread through the automotive industry and is now common across manufacturing. D1 forms the team, D2 describes the problem, D3 puts containment in place such as sorting or extra inspection, D4 finds the root cause and why the problem was not detected earlier, D5 chooses permanent corrective actions and shows that they work, D6 implements them and checks the effect, D7 prevents recurrence in processes, work instructions and similar products, and D8 closes the report. A D0 for preparation often comes first.
What does an 8D report depend on?
How useful an 8D is depends mostly on D4. A cause such as operator error or measuring error is usually a symptom; the question is why the process allowed the error and why inspection did not catch it. Tools include the fishbone diagram, five whys and comparing good and nonconforming parts. Where it is safe and practical, a strong case shows that you can make the error appear and disappear again with that cause.
How does an 8D report work in practice?
An 8D takes hours from manufacturing engineering and quality, often from the operator too, and sometimes sorting at the customer's site. Customers frequently set a deadline for each step. Like the hours of a non-conformance report, they can be booked against the order that caused the complaint. The larger effect often comes later: an action from D5 or D7 can change the route, for example with an extra measurement, a different setup or full inspection of one feature. Price the repeat order on the old estimate and that extra time is not in the price.
What is an 8D report often confused with?
An 8D report is not a non-conformance report: the NCR records one nonconformity and the decision on the parts, the 8D finds why it happened and prevents recurrence. Five whys and the fishbone diagram are tools within D4, not a substitute for the 8D.
Frequently asked questions
When does a customer ask for an 8D report?
Usually after a complaint about delivered parts, especially when the deviation reached the customer or has happened before. In automotive it is a common format; in other sectors customers often ask for one after a repeated or serious deviation.
Who pays for the action from an 8D?
That depends on the cause and on what was agreed with the customer. When the cause lies in your own process, you usually carry the cost. Once the action is part of the route, it belongs in the next estimate for that part.
Is an 8D only for customer complaints?
No. The same eight steps work for internal problems, such as recurring scrap on one operation. Customers mainly ask for the report after an external complaint.