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GLOBAL G8D-AN

OVERVIEW
• Welcome to the
PRESENTATION on
G8d-the most
powerful problem
solving tool
WHAT IS G8D?
• The global 8D process
seeks to define and
understand a problem.It
asks why a process is
operating outside of a
target range and provides a
mechanism for identifying
root cause and
implementing an
appropriate corrective
action.
Ford Global 8D process

*G8D is disciplined process which addresses problem solving


in a methodical and analytical way

*Each step of of the G8D process is preceded by the letter “D”


which stands for discipline

*Each discipline has an input and output

*The output for one step becomes the input for the next

*D0 is preparatory step that is new to the G8D process.


D0- Prepare for the global 8D process

D1-Establish the Team

D2-Describe the problem

D3-Develop the interim containment action

D4-Define and verify root cause and escape point

D5-Choose and verify permanent corrective actions

D6-Implement and validate permanent corrective action

D7-Prevent recurrence

D8-Recognize team and individual contributions


D0 –Prepare for the Ford global
8D Process
• In response to a symptom
,evaluate the need for G8D
process
• If necessary,provide
emergency response action to
protect the customer and
initiate the G8D process
Symptom: A quantifiable event or effect,experienced by customers
that may indicate the existence of one or more problems.
Example : Deck lid not opening on operating the motor
switch.

Problem: A deviation from an expectation ,a special cause, a


distribution within control limits that are too wide or any
unwanted effect.In the context of G8D problem solving
the cause is not known.
Example : Less amperage of motor coil.

ERA : Action taken to insulate and protect customers from a


symptom before 8D is initiated
Example : Replace the motor.
Tools and Techniques useful for
D0
• Reports of customer
satisfaction
• Trend charts
• Control charts
• Scatter diagram
• Vehicle audit Reports
• Rejection reports
D1 – Establish the Team
• The purpose of D1 is to establish a
small group of people with the
process and product knowledge
,allocated time ,authority and
skills in the required technical
disciplines to solve the problems
and implement corrective
actions.The group initiates the
team building process.
The types of team functions are

•Championing
•Leading
•Facilitating
•Time managing
•Scribing
•Recording
When Championing you

*Have ownership of the system of process


under consideration
*Have authority to make changes
*Make resources available to the team
*Support team decisions
*Attend meetings as required
*Create an environment for empowerment of
the team
*Use appropriate questions to monitor the
team’s progress.
When leading you
*are the team’s business manager
*are the spokesperson for the team
*work with the team to set objectives and tasks
*direct the usage of G8D methodology
*focus on the meeting’s purpose and agenda
*direct decision making
*explicitly give up the leadership role when
participating in discussion
When Time managing ,you
*allocate to each agenda item
*monitor meeting progress against the
agenda
*Keep the time for the team
*propose agenda time adjustments

When scribing,you
*record the leader’s summary
*restate and records team decisions during
meetings
*make team decisions visible
When Recording,you
*Translate meeting notes
*maintain records

When facilitating,you
*ensure that all members have the opportunity
to contribute
*focus on how the team is working together
*act as a team builder
*focus on team maintenance
*act as a team builder
*suggest process and maintain checks
*give and ask descriptive feedback.
When acting as a team member,you

* provide technical input


*carry out assignments
*offer information and ideas
*give descriptive feedback
*clarify issues
D2 – Describe the Problem
• The purpose of D2 is
to describe the
internal/external
problem by identifying
“What is wrong with
what”
The function of D2 is to

Identify the object and defect


Act as a database for describing the problem
Define the problem as accurately as possible

Any vagueness or inaccuracy at D2 can lead the team to wrong cause


followed by wrong corrective action.
Problem statement
IS IS NOT Additional Information

Object
WHERE WHAT

-------------------------------------------------------------------------
Defect

First seen
WHEN
HOW
BIG
D3 – Develop interim
containment action
• The purpose of D3 is to
verify and implement
Interim containment
action to isolate the effects
of the problem from any
internal/external customer
until permanent corrective
actions are implemented
D3 helps to
“buy time” to solve the root cause of the problem
Protect the customer from the effect of the problem
Distinguish between verification and validation
VERIFICATION
Proof developed before implementation that
the action will do what is intended by providing a before
and after data comparison and it does not introduce a new problem

VALIDATION

Ongoing evidence that the implemented action is doing


what was intended without introducing new problem.Validation
follows successful verification.
D4 – Define and verify root
cause and Escape point
• The purpose and function of D4
are to isolate and verify the root
cause by testing each root cause
theory against the problem
description and test data and to
isolate and verify the place in
the process where the effect of
the root cause could have been
detected and contained but was
not.
Possible cause:
Any cause,frequently identified on a cause and effect
diagram that describes how an effect may occur
Most likely cause:
A theory,based on available data ,that best explains the
problem description
Root cause:
A verified cause that accounts for the problem , verified
passively and actively ,by making the problem come
and go
Control system:
A system deployed to monitor the product /process and
ensure compliance to quality requirements
Control Point:
A location within the control system where the product/
process is checked for compliance to quality requirements
ESCAPE POINT:
The earliest location in the process,closest
to the root cause ,where the problem could
have been detected,but was not.

PROBLEM SOLVING WORK SHEET:

Problem statement and description

Comparative analysis

Root cause theories

Trial run of root cause theories


D5- Choose and verify
permanent Corrective Actions for
Root cause and• Escape Point
The purpose of D5 is to
select the permanent
corrective action to
remove the root cause and
address the escape point
after verifying that the
decisions will be
successful when
implemented and will not
cause any undesirable
effects
Decision making process:

Unilateral
Polling
Prioritization
Compromise
Consensus
DESCISION MAKING STEPS:
1)Describe the end result
2)List the decision criteria
a)The Givens must be
.Mandatory
.Realistic
.Objectively Measurable
b)The Wants are
.Desirable/Flexible
.Realistic
.Objective or subjective measurements
3)Decide on the relative importance of wants
4)Identify choices
5)Compare choices against decision criteria
6)Analyze the risk
7)Make a final balanced choice
D6-Implement and Validate
Permanent Corrective
Actions(PCA)
• The purpose of D6 is
to plan and implement
corrective
action,remove ICA
and monitoring long
term results
Problem prevention systematically
Reviews the steps of a plan and asks
.What could make make the
step/phase go wrong
.What can be done to prevent that
from creating trouble
.What needs to be done if it happens
anyway
.Who needs to initiate contingent
action
D7- Prevent Recurrence
• The purpose and function
of D7 is to modify the
necessary systems
including policies and
procedures to prevent
recurrence of this problem
and similar one and to
make recommendations for
system improvements as
necessary
Resources for completing D7

Procedures

ISO and QS procedures

Process flow

Control plans

Lessons learned by team


D8 – Recognize Team and
Individual Contributions
• The purpose of D8 is
to complete team
experience,sincerely
recognize both team
and individual
contributions and to
celebrate
Why Recognition and celebration
Recognition encourages team members

Recognition says doing a good job matters

Recognition says the organization is result


oriented

Recognition should be fit ,focused and timely


Completion of unfinished Team business

 Finalizing and archiving documentation

Recognizing technical lessons learned

Making the final presentation to champion

Expressing gripes and regrets to team members

Expressing appreciation to team members

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