Strengthening Problem-Solving Capability Through 8D Assessments

Effective problem-solving is at the core of continuous improvement and lean thinking. Many manufacturing organisations struggle to build the right skills, habits and leadership behaviours needed to address recurring issues.

That’s where the 8D Assessment comes in, it provides a structured evaluation of your current problem-solving capability, behaviours and leadership engagement.

Why an 8D Assessment Matters

When problems keep recurring, cost rises, waste accumulates and doubt grows. Without a robust method, teams revert to firefighting rather than fixing root causes. An 8D Assessment offers:

• Clarity on current practice, what is actually happening on the plant floor

• Insight into the use of problem-solving tools, training and systems

• Evaluation of leadership support for problem-solving, governance and escalation

• Identification of capability gaps and priority areas for developmentBy assessing these dimensions, you build a strong foundation for deployment and continuous improvement.

  
  

What the 8D Assessment Covers

Our three-phase process includes:

1. Understanding current problem-solving practices

   • Interviews with leaders, practitioners and team members

   • Observation of behaviours and their impact on performance

   • Review of recent problem-solving efforts and outcomes

2. Evaluating systems and tools

   • Examination of the use of 8D or A3 frameworks

   • Assessment of problem-solving training and coaching systems

   • Review of data and trends to understand repeat problems

3. Exploring leadership’s role

   • Analysis of how leaders support and enable problem-solving

   • Review of behaviours such as removing barriers, prioritising issues, and fostering accountability

   • Assessment of the environment for collaboration and learningThis depth of review allows you to see not just what is broken, but why and what needs to change to raise capability sustainably.

     
     

How It Strengthens Productivity Deployment

During Step 3 of the Productivity Partnership - Productivity Deployment - execution and stability are key. An 8D Assessment supports this by:

• Ensuring problem-solving capability is aligned with your deployment strategy

• Building stronger leadership support so improvements are embedded

• Reducing recurrence of issues which can derail productivity gains

• Enhancing your system of escalation and accountability

• Supporting a culture of effective, repeatable problem-solving rather than ad-hoc fixesThis means your deployment becomes more predictable, resilient and effective.

Practical Outcomes You Can Expect

Following an 8D Assessment you can expect:

• A clear diagnostic of problem-solving capability, systems and leadership behaviours

• A prioritised list of improvement opportunities in problem-solving and root-cause analysis

• Recommendations on training, tools and leadership practices needed to elevate capability

• Stronger alignment of problem-solving practice with your strategic and operational improvement plansUltimately, this increases your ability to solve problems permanently — which supports higher productivity, fewer disruptions and stronger performance.

Conclusion

Problem-solving capability is a critical enabler of sustainable productivity improvement. An 8D Assessment gives you the insight, clarity and focus needed to lift your organisation’s capability, aligning tools, behaviours, leadership and systems. As part of the Productivity Partnership, this assessment strengthens your deployment phase by ensuring that when problems occur, your team responds with disciplined, effective action and lasting solutions.

Strong problem-solving builds strong performance. And strong performance builds strong manufacturing operations.