How is an 8D report completed?

2025-12-02

In global supply chains, rapid response and thorough resolution of quality issues are fundamental competencies for any mature manufacturing enterprise. As a company specializing in the forging and manufacturing of metal components such as aluminum, copper, and steel, we understand that quality not only underpins customer trust but also determines our long-term competitiveness in the international marketplace.

Recently, we received a quality complaint from an overseas client—a small number of forged components in a delivered batch exhibited cracks. Though minor, the issue demanded immediate attention. Our company immediately initiated the 8D Report problem-solving process. Through structured, data-driven, and team-based approaches, we advanced from initial issue containment to ultimately preventing recurrence, ensuring a precise and reliable response to the customer.

1. Rapid Formation of Cross-Departmental Task Force (D1)
Upon receiving the complaint, we swiftly assembled a task force comprising Quality, Process Engineering, Production, Equipment, and Tooling departments. This team assumed full responsibility for investigating and resolving the incident, ensuring rapid coordination across all stages. During the meeting, we clarified individual roles and responsibilities and initiated an in-depth investigation.

2. Define Problem Scope and Details (D2)
The task force systematically analyzed the issue using the 5W2H method, identifying its characteristics, affected batches, occurrence locations, and quantity ratios. This established an objective and accurate foundation for subsequent investigations.

3. Implement Temporary Containment Measures (D3)
To prevent disruption to customer production, our company implemented temporary measures including suspending relevant production lines, conducting 100% re-inspection of inventory and work-in-progress, and strengthening specialized inspection items to ensure the issue did not recur.

4. Root Cause Investigation (D4)
Through multi-dimensional inquiries including process tracing, mold inspection, equipment record analysis, and material re-testing, the team identified the root cause: during specific work shifts, the combination of heating temperature control and mold wear led to localized stress concentration during forming, triggering cracks. This finding was reviewed and confirmed by an internal expert panel.

5. Develop and validate corrective actions (D5)
Addressing the root cause, our company implemented a series of corrective measures including mold structure optimization, temperature control system upgrades, enhanced forging press pressure monitoring, and standardized work procedures. Their effectiveness was validated through testing and inspection.

6. Fully implement permanent improvement measures (D6)
The corrective actions have been formally integrated into the production system. Relevant personnel have undergone retraining to ensure all changes are fully implemented.

7. Establishing Long-Term Prevention Mechanisms (D7)
This case has been incorporated into our quality system database. Preventive capabilities are further strengthened through increased mold inspection frequency, enhanced process parameter traceability, and ongoing automation of critical processes.

8. Team Collaboration and Continuous Improvement (D8)
team involved in resolving this issue and organized an experience-sharing session, laying the foundation for future quality enhancements.

INNOVAW consistently prioritizes customer experience. The swift response and rigorous handling of this incident not only demonstrate our robust quality management system but also reinforce our professional standing within the global forging industry. We remain committed to advancing continuous improvement with a strong sense of responsibility, delivering higher-quality, more reliable metal forging products and services to customers worldwide.