8D Problem Solving

8-D is a quality management tool and is a vehicle for a cross-functional team to articulate thoughts and provides scientific determination to
details of problems and provide solutions. Organizations can benefit from the 8-D approach by applying it to all areas in the company. The
8-D provides excellent guidelines allowing us to get to the root of a problem and ways to check that the solution actually works. Rather than
healing the symptom, the illness is cured, thus, the same problem is unlikely to recur.
Step 0 1 2 3 4 5 6 7 8
Action The Planning Stage Establishing Problem Developing Identifying & Identifying Implementing Preventing Recognizing
the Team Definition / Interim Verifying Permanent & Validating Recurrence Team Efforts
Statement & Containment Root Cause Corrective PCA
Description Action Actions (PCA)
The Planning Stage: - Divide the work to team member depending on
The 8-D method of problem solving is appropriate in "cause individual skills.
unknown" situations and is not the right tool if concerns center - 8D report must apply to fully understand of this
solely on decision-making or problem prevention. 8-D is
common issue.
0 especially useful as it results in not just a problem-solving
process, but also a standard and a reporting format. Does this
problem warrant/require an 8D? If so, comment why and
proceed.

Establishing the Team: Team Goals:

Establish a small group of people with the process/ product - Search for the reason and the solution of cracked Bearing
1 (Tapered roller bearing) after 1000 km
knowledge, allocated time, authority and skill in the required
technical disciplines to solve the problem and implement - wright the problem solving in scientific paper
corrective actions.
Department Name Skills Responsibility
Construction Omar I. M. Rajab Prepare reports 8D Report
Industry Mohammed Dilan Burhan Scientific Research Essay
Construction Naguib Victor Naguib Farag Failure analysis FMEA
Logistic Ribeiro Telli Guilherme Scientific writing Essay

Problem Definition Sketch / Photo of Problem

Provides the starting point for solving the problem or
Nonconformance issue. Need to have “correct” problem
2A description to identify causes. Need to use terms that are
understood by all.

Item name: Tapered roller bearing

List all of the data and documents that might help you to
define the problem more exactly? FMEA, Examination,
Analysis, Material testing,

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 8D Problem Solving

2B IS IS NOT
Who is affected by the problem? Who is not affected by the problem?
The operation, assembly, quality control, production,
purchasing
Who

department of materials, logistics, marketing, customer,

supplier

What has the problem (part id, lot #s, etc)? What does not have the problem?
Supplied parts do not meet the required quality
What

Why is this a problem (degraded performance)? Why is it not a problem?

The bearing play vital rule in working of any machine, so the The bearing can still work after the crack happened.
Why

cracked bearing it maybe goes to full damage of the bearing,

that is mean the machine can’t work

Where was the problem observed? Where could the problem be located but is not?
In the bearing sometime in the outer ring, or interring or even in In the cage, balls
Where

the roller

When was the problem first noticed? When could the problem have been noticed but was not?
After working machine for sometime In the factory during the production
When

Quantity of problem (ppm)? How many could have the problem but don’t?
How Much/ Many

It can happen in any bearing any time

How much is the problem costing in dollars, people, & How big could the problem be but is not?
time?
The price of the new bearing, since if that happens then you
need to change it.

What is the trend (continuous, random, cyclical)? What could the trend be but is not?
How Often

Problem Description
(based on the information gathered so far, provide a concise problem description)

Precision ball bearings are designed to have a long and useful Life. Assuming the application is correct, to begin with, maximizing
longevity means bearings must be properly installed, lubricated and maintained. Poor operating environments. particularly moist or
contaminated areas. and improper handling practices invite premature bearing failure.

2C When a bearing does fail, it is important to determine the exact cause so appropriate adjustments can be made. Examination of the failure
mode often reveals the true cause of failure. this procedure is complicated by the fact that one failure mode may initiate another. For
example, corrosion in a ball race leaves rust-an abrasive-which can cause wear, resulting in loss of preload or an increase in radial
clearance. the wears debris can, in a grease-lubricated bearing, impede lubrication. resulting in lubrication failure and subsequent
overheating.

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 8D Problem Solving

Developing Interim Containment Actions

Temporary actions to contain the problem and “fix” until a permanent correction is in place - document actions in Action Item Table
3 Repair parts in inventory, in stock, at a supplier, work in process, in shipping
Repair parts at customer

Identifying & Verifying Root Cause (Brainstorm)

Analyze for “Root Cause” of the problem. Identify and verify the Escape Point
Excessive interference
Excessive load, shock load
4 Progression of Flaking
A Heat generation and Fretting caused by contact between mounting parts and raceway ring
Heat generation due to Creep
The poor taper angle of the tapered shaft
Poor cylindricality of shaft
Interference with bearing chamfer due to a large shaft corner radius

4 Cause and Effect Diagram

A
EXAMINATION

Visual examination
We search for marks of spalling, brinelling or track markings, the purpose of the inspection is to determine the overall condition of the roller-bearing.
Macroscopic analysis
The cone, rollers, and cage under low magnification using a stereo zoom microscope we can see the deep groove and the crack.
Microstructural analysis
Longitudinal cut sections of a roller and cone can show tempered martensite, distribution of carbides, detrimental feature, decarburization
(indicating about the heat treatment).
Hardness analysis
Hardness profiles take it near the surface of roller and raceway surface of the cone to measure the hardness.
Retained austenite measurements
Retained austenite measurements can be carried out on roller surface, raceway of the cone.
Wear debris analysis
The metallic wear debris particles by using image analyzer, analyses the wear debris collect in the filter paper. Then we can determine the metallic
wear debris particles size range and non-metallic particles size range.
Liquid-penetrant examination:
All the surfaces of the inner and outer rings should examine with a red-dye liquid penetrant
The chemical analysis
To understand the exact composition of the material of the bearing

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 8D Problem Solving
Analysis

4
B

4
C

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 8D Problem Solving

5 Identify Permanent Corrective Actions

solutions that address and correct the root cause. Solutions determined to be the best of all the alternatives

Lubrication Failure Since ball bearings rely on proper lubrication of critical areas such as between the bearing rings, balls,
cage, and races, it is imperative to lubricate these parts well. Excessive temperatures and restriction to
lubricant flow, however, impacts the lubricant’s properties.
Contamination Filter the lubricant and clean work areas, tools, fixtures, and hands to reduce the risk of contamination.

Improper Mounting Follow proper mounting instructions and provide training to ensure all employees understand the difference
between a properly and improperly installed mounting.
Misalignment Inspect shafts and housings for runout of shoulders and bearing seats, and use precision-grade locknuts.

False Brinelling Eliminate or absorb external vibration that could cause the balls to move. Also, be sure to use lubricants
containing anti-wear additives.

Corrosion Utilizing stainless steel bearings and external and integral seals
Using these techniques particularly in a hostile operating environment
Keeping corrosive fluids far from the bearing areas.
Electrical Damage Prevent electrical currents from flowing through the bearing by grounding or using insulated bearings.
(Fluting)

Fatigue (Spalling) Replace the bearing and/or consider a redesign that uses a bearing with greater calculated fatigue life,
internal clearances, and proper shaft and housing recommendations.

Overheating Provide adequate heat paths, supplemental cooling, and overload, and thermal controls to prevent this
problem.

Excessive Loads Minimize the load. It also helps to redesign and use a bearing with greater capacity.

Improper Storage and Store bearings in a dry area at room temperature.

Handling
Fit Make sure a proper clearance is selected to avoid fit issues. Refer to the manufacturer’s installation guide.

Reverse loading The best way to correct this issue is proper bearing installation:
Install the angular contact bearings with the resultant thrust (marked “thrust”) on the wide side face of the
outer ring, as well as the inner ring’s opposite face.
True brinelling avoid pushing the outer ring as you place the inner ring onto the shaft. Applying the right amount of force to
the ring that is being press-fitted when you install bearings is also advisable.
False brinelling Make it a point to apply lubricants that contain molybdenum disulfide or other anti-wear additives. These
additives isolate the bearing from external vibration. Use these greases for bearings in actuator motors that
tend to reverse or oscillate rapidly.

6 Implementing & Validating the Permanent Corrective Action(s)

Implement and validate to ensure that corrective action does “what it is supposed to do.” Detect any undesirable side effects. Return to root
cause analysis

Level Action to be taken Planned Actual

Managerial

1- Making sure that the regulations are well

understood within the employees
2- Selecting enough experienced employees
by agreement with the HR department
3- Organizing periodical meetings with Monthly Every 40 days
employees
4- Training courses Half a year Yearly
5- Following up any customer complain
starting from reviewing previous informed
problems
Technical

1- Making sure that everyone is well

acquainted with the processes
2- Documenting any technical problem and
excluding the improper item
3- Applying a high standard bearing Within 2 weeks One month
simulation from storing the materials until
delivering it to the customer

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 8D Problem Solving

Preventing Recurrence
determines what improvements in systems and processes would prevent the problem from recurring. Ensure that corrective action remains
in place and successful
7

Responsible Verifie Date Implemented

d Y/N

Where appropriate - ✓ FMEA 10. Excessive Loads Safety control Y 20-01-2019

Update these items X FMEA 6. Corrosion Quality control N
to reflect changes:
✓ Improper Storage and Handling Warehouse-men Y 29-01-2019
✓ Simulation Technical Dep. Y 30-12-2018
X Reviewing any previous customer complain DC N

8
Before

After

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 8D Problem Solving

We achieved a remarkable jump in the market by decreasing the causes of bearing failure thanks to our team. And we can see her we are
achieving a leap in the rate of selling this year which I hope to continue the same way.

I can’t say but just your cooperation and diligence have made our project much easier and work smoothly. I really appreciate your time
and effort.
Congratulations on your success. You have made us all proud. Keep up the good work

Celebrate the successful conclusion of the problem-solving effort

An additional incentive will be disbursed for all the employees.

THANK YOU

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