8D Approach to Improve Productivity for Manufacturing Industry

Rahul Patil; A. R. Balwan

doi:10.55524/ijirem.2025.12.2.17

Abstract

In today’s competitive manufacturing landscape, companies must prioritize defect reduction to enhance product reliability and market sustainability. This study investigates the application of the 8D (Eight Disciplines) problem-solving methodology to minimize rejection rates in counterweight production. The research focuses on identifying root causes of defects—such as ovality, burrs, and rust—through structured analysis and implementing corrective actions. Perfection in the quality of process and product is important to grow in a competitive era. Manufacturing issues are exceptionally vital, need careful and quick consideration something else it harms to company’s profit margin and reputation There are several methods used for increasing efficiency of company like 7QC tools, FMEA, PPAP Six Sigma etc. The 8D strategy is a point by point, team-oriented approach to settling troublesome generation issues. The objective of this strategy is to distinguish the root cause of an issue, plan control measures to ensure clients. 8D technique is familiar to solve problems, reduce the quality cost and it increases customer satisfaction. This research analysis confirm that number of defects are generated during manufacturing of product ,they can affect the productivity.8D technique which is a bundle of systematic approaches parallel uses of various quality dimension tools to find the root cause of badly-behaved element. By forming cross-functional teams and employing quality tools like Pareto charts, Fishbone diagrams, and 5-Why analysis, the rejection rate was reduced from 31.5% to 3% within three months. The results highlight the efficacy of 8D in improving process efficiency, reducing waste, and increasing customer satisfaction.

Keywords

FMEA, RCA, Fishbone diagram, 8D Method, Pareto Chats, 5-Why,corrective action

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Cites this article as

R. Patil, A. R. Balwan, "8D Approach to Improve Productivity for Manufacturing Industry", International Journal of Innovative Research in Engineering & Management (IJIREM), Vol-12, Issue-2, Page No-106-113, 2025. Available from: https://doi.org/10.55524/ijirem.2025.12.2.17