Each person involved in problem-solving according to the 8D Methodology must be aware that Interim Containment Actions (ICA) can be applied not only in step D3 but also in D0, defined as the Problem Statement.
In the latter case, ICA can be initiated as part of Emergency Response Actions (ERA), which are determined after assessing whether the client-reported issue is related to safety or requires urgent resolution. It is important to note that ICA addresses the symptom of the problem (i.e., what is reported by the client) rather than the root cause. Permanent Corrective Actions (PCA), defined in step D5, eliminate the root cause and thereby the symptom itself.
Of course, the effectiveness of both ICA and PCA activities should be thoroughly verified.
Key questions for Interim Containment Actions
During the definition of interim containment actions, we should ask ourselves the following questions:
- Are we still producing defective products?
- Do our control processes require increased sampling frequency or a change in the measurement method?
- Should the issue be escalated to the supplier?
- Could the actions we plan to take cause additional problems?
These actions must be implemented immediately after identifying the problem and must eliminate the effects caused by defective products. The goal of ICA implementation should focus on limiting the impact of the problem identified by the final customer, reducing the occurrence scale, and minimizing the final costs of poor quality.
Examples of Interim Containment Actions
There are various ICA strategies, depending on the severity of the problem reported by customers. Examples include:
- Temporary 100% sorting of components
- Additional inspection of finished products before shipment
- Additional measurements and tests during production
- Increased frequency of tool changes
- Limiting production to a single source (in the case of dual sourcing)
- Changing the manufacturing cell
- Requesting 100% inspection of materials from Tier 2 suppliers
- Notifying the client about non-conforming products
- Immediate repair of machinery or tools
- Additional quality control operations
- Introducing sorting actions at all points in the supply chain
- Halting and isolating suspect materials
Benefits of ICA Implementation
The primary benefit of implementing ICA is ensuring the safety of finished products and minimizing costs associated with quality issues. Prompt and appropriate responses allow us to avoid potential expenses related to:
- Scrapping or repairing non-conforming products
- Special transportation to customer facilities
- Initiating additional production shifts
- Conducting product inspections at customer warehouses
- Launching recall campaigns in the field
It is crucial to remember that ICA activities are implemented for a defined time period, as they incur significant costs, including increased cycle time, additional labor inputs, and higher raw material expenses.
Additional Resources
You can download an automatic, editable Excel form for free on Free Quality Tools.
Document name: 8D Report β Excel Form
: D3 in the 8D Methodology){kind=link}