The 8D Methodology in Electronics Manufacturing Services
Company Ltd in the 1980s, aimed to address the problems occurring in the car manufacturing process. Today it is widely adopted by many other industries including electronics production. This article explores the principles of the 8D methodology and its significance for electronics manufacturing services (EMS) and original electronics manufacturers (OEMs).
Fundamental concepts of the 8D methodology
The 8D methodology or the Eight Disciplines of Problem Solving is one of the most effective systematic approaches to dealing with problems in a comprehensive way.
It promotes precise problem identification and detection of its causes. It supports the development and implementation of short-term and permanent solutions, while it also enhances the production and quality testing procedures to avoid the reoccurrence of resolved issues.
With this strategy, an EMS provider not only fixes the results of errors but also gets useful insights.
Process of problem-solving with the 8D methodology
EMS providers who have implemented this approach start with the identification of a problem and resources for its resolution. They establish a team of specialists for problem-solving, assign responsibilities and roles and move to the problem description. The determination of the underlying issues is conducted with the help of the 5W1H method (why, what, who, where, when and how).
For more complex problems, contract manufacturers develop a quick temporary solution or an Interim Containment Action (ICA). ICAs give momentary crisis relief while the Root Cause Analysis (RCA) is performed. When the underlying causes are known, manufacturers develop a Permanent Corrective Action (PCA) and set criteria for failure detection.
Once a PCA is designed, it can be implemented. PCAs and their implementation time vary depending on the nature of the problem. They can be as simple as an extra controlling procedure or an entirely new process.
The next stage is the implementation of an error prevention method. Such experienced manufacturers as Assel use the effective Poka-Yoke technique for this purpose. The process is finished with a report and discussion of the results.
Altogether, there are a preparation phase and eight stages.
8D methodology – benefits for OEMs
Every OEM is interested in producing reliable products of high quality and minimising manufacturing costs, which helps to gain greater income. Co-operation with an EMS provider who has successfully adopted the 8D methodology helps to achieve all of the business goals.
The Eight Disciplines of Problem Solving is the process allowing to address a variety of diverse critical production problems.
First of all, working with a contract manufacturer who complies with this methodology makes it easier for OEMs to meet regulatory or safety standards. It also simplifies the process of obtaining certificates.
Secondly, the 8D methodology is a powerful tool that can be used for identifying and solving warranty issues and customer concerns. While the task of your EMS provider is manufacturing devices strictly according to the specification of your project, mistakes can still take place. Yet, a contract manufacturer relying on the 8D methodology will be able to detect and fix errors more efficiently.
Furthermore, if your design turns out to be faulty, the 8D methodology will make it possible to identify the underlying issues of test failures.
Finally, working with an EMS provider who uses the Eight Disciplines of Problem Solving is more financially profitable as the methodology also searches for the possibilities to reduce scrap and waste.
Improve production efficiency with the 8D methodology
To minimise production errors, receive the devices meeting your requirements and reduce manufacturing costs, choose an EMS provider working in line with the principles of the 8D methodology. If you are interested in learning more about the optimisation of electronics production, go to asselems.com.