Global 8D – D3: Develop an Interim Containment Action (ICA)

Having already put into place an emergency response action (ERA), the G8D Team now need to replace this with a more considered ICA.

In this article I will describe and discuss the Interim Containment Action (ICA).

Like all structured problem solving methodologies, the continuous review of the G8D Team composition is important to ensure that the team has all the right skills and knowledge to maximise the problem solving efforts.

Having established that we have a problem we need to protect the customer (internal or external) from the effects or symptom of the problem. This is done for two reasons: 

• To ensure the customer has minimal or no impact felt as a result of the problem 
• To buy time for the problem to be investigated and solved

Having already put in place an ERA the team now to apply a more considered option to portect the customer, and that is the ICA. By its nature, an ICA will normally be expensive to implement as it will probably involve an additional process being introduced and could include:

• 100% Inspection
• Rework
• Sorting good from bad
• Field service action

As can be seen, any one of these actions would add considerable cost, however they are necessary to protect the customer. Remember that some of the above actions are not 100% effective, even 100% inspection is subject to variation.

Note: Sometimes the ERA might be considered as the best ERA. In these cases, make sure this is recorded and why.

An ICA is, as it states, interim. The Global 8D process drives learning about the problem to enable a fuller understanding of the problem so that, in some cases, a more cost effective containment action can be derived.

Example: An automotive manufacturer was experiencing water leaks between the inner and outer front wing of a vehicle under water test at the factory. The ICA was to add a thin bead of mastic sealant the whole length of the inner wing before welding the inner and outer together. Once the problem was better understood the length of the mastic sealant applied was reduced to one small area. When making several hundred a day, these few seconds and material savings were significant. 

The choosing and implementation of the ICA uses the Deming Plan Do Check Act Cycle.

PLAN – Chose the most effective ICA and plan its implementation. This will involve verifying that the ICA is effective and that all the necessary work instructions, resources and equipment are made available, on time. It is important to ensure that the ICA is made “official” for accounting and operational purposes.

DO - Implement the ICA as per the plan, ensuring that the action is clearly communicated at operational and management levels.

CHECK - Check that the ICA has been implemented exactly according to the plan and that it continues to be effective.

ACT – Take action to ensure ICA remains effective and sustained within daily operations as necessary.

Assessing Questions

• Are ICAs required?

• Is a Service Action required as part of the ICA?

• What can you learn from the ERA that will help in the selection of the ‘best’ ICA?

• Based on consultation with the G8D Customer and Champion, have criteria been established for ICA selection?

• Based on the criteria established, does the ICA provide the best balance of benefits and risks?

• How does this choice satisfy the following conditions?

  • The ICA protects the customer 100 % from the effect.

  • The ICA is verified.

  • The ICA is cost-effective and easy to implement. 

Complete the G8D Form (Template)

Complete the Global 8D form and circulate. Remember to update team composition for any changes that are made at the end of this stage.

The G8D form is a summary of the problem solving activity and is supported by all of the other worksheets, data and supporting information that is generated as a results of the problem solving activity.

Ensure that a a full account of the ICA and supporting documents are alailable to support this summary.

Graham Cripps 

Results Consortium Ltd