Case Study 3

Case Study 3: Root Cause Analysis and 8D Methodology Training,  Plastic polymer compounds raw material production industry, Tier 2 supplier 

Challenge

A mid-sized UK-based manufacturer of polymer resins and recycled plastic raw materials. Recurring delays in order processing and root cause investigation feedback given to customers complaints with 8D analysis, support also for the sales office and the production floor to maintain low warranty costs and production rework.

Training Program Design

  • The company commissioned a structured Root Cause Analysis (RCA) and 8D training for its 10-person office management team. 
  • Participants: 10 members (Office Manager, Customer Service, Logistics, and Quality Admin).
  • Format: 2-day intensive workshop focused on “learning-through-doing” using real-office scenarios.
  • Methodology: The global 8D process training with real life plant relevant examples for efficient problem-solving has been interactively discussed with the participants. 

The 8D Process Application (Workshop Example)

Participants applied the eight disciplines to a repeat administrative error: Incorrect raw material grade shipped to a key client. 

  • D1 (Team): Formed a cross-functional team of the 10 participants.
  • D2 (Problem Description): Used the 5W method (Who, What, Where, When, Why) to quantify the error.
  • D3 (Containment): Identified and quarantined all pending orders for that specific resin grade.
  • D4 (Root Cause): Conducted a Fishbone (Ishikawa) Diagram and 5 Whys analysis. They discovered the root cause was not human error, but an outdated dropdown menu in the ERP system.
  • D5–D7 (Corrective & Preventive): Implemented system-wide software updates and revised the “Office-to-Floor” communication protocol to prevent recurrence. 

 

Follow-up & Certification 

Examination: On day two, all 10 participants sat a written exam to verify their understanding of RCA tools and the 8D sequence.

  • Certification: Upon passing, delegates received certificates for their attendance and examination results.  
  • Impact: The manufacturer saw a reduction in time to close 8D reports and a significant improvement in cross-departmental collaboration within six months.