Case Study 3: Root Cause Analysis and 8D Methodology Training, Plastic polymer compounds raw material production industry, Tier 2 supplier
The Challenge
A mid-sized UK-based manufacturer of high performance PP compounds supplied into the automotive and white goods markets. Changes in the organisation and aquisition of additional staff required a skillset upgrade to alow effective participation in problem solving and root cause investigation to support the business.
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 (Senior Management, Customer Service, Logistics, Production, Technical and Product design, and Quality Management).
- Format: One-day intensive workshop focused on “learning-through-doing” .
- Methodology: The global 8D process training with real life plant relevant examples for efficient problem-solving has been interactively discussed with the participants.
- Problem solving tools (5 Why; Ishikawa Diagram, Is/Is not ) were included in the training and explained to all participants using selected real life examples investigated.
Outcome, Implementation and Success Factors:
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.
