D7 step – Prevent Recurrence in 8D

What Is the D7 Step in 8D? #

After verifying that your corrective actions were effective in D6, the next discipline is D7: Prevent Recurrence. This ensures the lessons learn from this problem are consider permanently into your systems.

In short, D7 transforms learning into standardization.

It focuses on updating documentation, revising procedures, training people, and deploying improvements across similar products or processes.

“A problem that reappears is a ignorance, D7 makes sure that never happens again.”

Therefore, the objective of D7 step is to:

• Integrate corrective actions into the company’s management and quality system.
• Prevent the same issue from reoccurring in the same or other products.
• Apply “Horizontal Deployment” which make improvements to all similar lines or components.
• Document changes in FMEA, Control Plan, Work Instructions, and Standards.
• Train relevant personnel on updated requirements.

How to prevent recurrence in 8D analysis? (Explained) #

Let’s go through each one.

Step 1 – Standardize the Improvement #

Every effective corrective action must be updated in controlled documents.

Typical List of applicable documents are:

These updates ensure the solution is part of your Quality Management System (QMS), not just an change event.

Step 2 – Apply Horizontal Deployment #

“Horizontal Deployment” means applying the same learning to all similar products, processes, or equipment that could face the same issue.

For example, if the gas regulator issue occurred in Welding Line 2, similar regulators in Line 1 and Line 3 should be checked too.

By making improvements across lines, the company prevents similar failures before they happen.

Step 3 – Train and Communicate #

Training ensures that everyone understands the new changes and applies them correctly.

Actions to include:

• Conduct training for weld operators on new inspection lighting standards.
• Train maintenance team on updated PM checklist for gas regulators.
• Record attendance and include training reference numbers in your report.
• Display “Do’s and Don’ts” visual aids near welding stations.

Example Entry in Remarks:

“Training completed for 18 operators and 3 maintenance personnel on 25 Oct 2025 (Ref: TRN-QA-08). Visual work instructions updated at workstation.”

Step 4 – Audit and Verify Effectiveness of Prevention #

To confirm standardization is working:

• Conduct an internal audit on the revised documents and implementation.
• Verify that updated FMEA and Control Plan reflect new controls.
• Check that new operators follow the updated process consistently.

Verification Method Example:

During layered process audit (LPA) on 30 Oct 2025, all weld lines verified for regulator PM compliance – no deviation found.

Step 5 – Capture Lessons Learned #

Your final responsibility in D7 is to make the learning accessible to future projects.

• Add this case to the “Lessons Learned” database.
• This database use to reference in new APQP or DFMEA reviews for future seat models.
• Update supplier guidelines to include gas-flow checks during audits.

Example Entry:

Lesson Learned #LL-25-2025:
“Gas regulator O-ring wear caused weld weakness. Added PM schedule and lighting standards. Prevented recurrence across 3 welding lines.”

Step 6 – Verify Customer Satisfaction #

The validation of D7 completes when the customer confirms stable quality over time.

Example of such Feedback from customer:

“No recurrence of weld defects observed in the past 4 weeks; process change verified by XYZ Motors Quality Audit.”
— Customer E-mail Confirmation, 10 Nov 2025

Attach this approval as evidence in your report.

Tools Used in D7 step #

Step 7 – Filled Example in Your Template #

How D7 Links to next steps

Once you prevent recurrence, the next steps is 8D closure:

1. D7 – D8 (closure) = Proven corrective actions are now standardized and deployed. Closure depends on confirmation that systems are updated and the team is recognized.
2. D7 – FMEA / APQP / Lessons Learned = Knowledge integrated and used as long-term organizational learning.

Summary of Prevent Recurrence step #

• D7 ensures systemic prevention, the fix becomes part of your company’s DNA.
• Update all relevant process documents and train personnel.
• Use horizontal deployment to share the learning across all similar areas.
• Verify effectiveness through internal audits and customer validation.
• Capture the lesson learned for future projects.

“Solving a problem helps today; preventing it everywhere secures tomorrow.”