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Global 8D Process
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Global 8D ProcessExecutive Overview
Presented by: Mohamed O. EzzatPTP STA Manager
Agenda What is Global 8D? Why Ford developed Global 8D Why Ford involves suppliers Development of the G8D concept The Ford Global 8D computer system Success Factors for ROI Global 8D support available
Problem or Opportunity?Within each problem lies a disguised opportunitybut it is the art of unmasking the disguise that distinguishes between the two.
Anonymous
Problem Recognition No matter how large
the tip of an iceberg seems, 80 percent of it lies below the surface of the water.
Its the same way with problems.
Symptom
Real Problem
Background of G8D G8D is the result
of combining the best-practices of several methodologies
G8DG8D
Global 8D DefinedA disciplined, systematic process for solving problems and preventing their recurrence
Global 8D Functions Problem-Solving Process
Global 8D Functions Problem-Solving Process Standard
Global 8D Functions Problem-Solving Process Standard Communication Tool
D1
D2
D3
D4
D5
D6
D7
D8
D0 Prepare for the Global 8D Process
Establish a Team
Describe the Problem
Develop an Interim Containment Action
Define & Verify Root Cause & Escape Point
Choose & Verify Permanent Corrective Actions
Implement & Validate Permanent Corrective Actions
Prevent Recurrence
Recognize Team & Individual Contributions
Why Ford Developed G8D
Best Allocation of Time
Cost of ResolvingProblems
Actual Time Spent
PASTProblemSolving
Low
3 - 5 x
80%
PRESENTDecisionMaking
Medium
x
10%
FUTURE
Planning
High
.1 x ?
10%
Focus of G8D Steps
ProblemSolving
DecisionMaking
Planningand
Prevention
D2D4
D0, D1,D3, D5,
D8
D6D7
Inhibitors to Effective Problem Solving
Jumping to conclusions Bias Lack of factual data No logical process Impatience Failure to use
corrective actions Etc.
G8D Highlights Never-Been-There and Change-
Induced conditions Root Cause and its
Escape Point Prevent Recurrence One global system Assessing Questions Common Tasks
Change-Induced vs.Never-Been-There Situations
Level ofPerformance
Time
Expectation
Something Changed Gradually
Actual
Change-Induced vs.Never-Been-There Situations
Level ofPerformance
Time
Something Changed Abruptly
Expectation
Actual
Change-Induced vs.Never-Been-There Situations
Level ofPerformance
Time
Never-Been-There
Desired
Actual
Addressing Alternative Problems
l Change-Induced Conditionsl Multiple Cause
Ford Suppliers and G8D
Quality in products Reduce costs Improve
communication
QS 9000
Fords Partnership with Suppliers
Ford doesnt have a chance at world-class quality if parts arent defect free
Process Control?
D - Prepare for the G8D Process
Use G8D? Emergency Response
Action?
D - G8D Application Criteria
G8D?
Process Improvement?
Robustness?
Triz?
Symptom quantified?
Customer identified? Symptom priority or
performance gap? Cause unknown? Mgt. committed? Team needed?
D1 - Establish the Team Identify the Champion
and Team Leader Determine the skills and
knowledge the team will need
Select team members Establish team goals,
roles, and how to work together
Tell Me What the Problem Is
INSTRUCTIONS Read the first short
scenario in your portfolio
Write what you think the problem is
Time: 1 minute
D2 - Describe the Problem
Identify what is wrong with what
Detail the problem in factual, quantifiable terms
D2 - Describe the Problem
l Problem Statementn Whats wrong with what?n Why? Why? Why?
D2 - Describe the Problem
Problem Description WHAT
the problem IS and IS NOT WHEN
the problem IS and IS NOT WHERE
the problem IS and IS NOT HOW BIG
the problem IS and IS NOT
D3 - Develop the Interim Containment Action
Isolate the customer from the effects of the problem
Verification Proof before the action
is implemented that the action will do what is intended
Validation Ongoing evidence that the
action is doing what was intended
D4 - Define and VerifyRoot Cause and Escape Point
Test each possible cause against the D2 problem description
Identify where the problem should have been detected
Verify the root cause and escape point
D4 - Root Cause Analysis
IS / IS NOT
Differences
Changes
Test
Potential Root Cause(s)
D4 - Verify the Root Cause
Make the problem come and go
ProblemProblem
D4 - Escape Point The place in the
system closest to the root cause where the problem could have been detected but was not
D5 - Choose and Verify Permanent Corrective Actions
Select the best PCA to remove the root cause
Address the escape point
D5 - Choose and Verify Permanent Corrective Actions
l Decision-Making WorksheetDecision Making Worksheet
Givens Choice A Choice B
Wants
Risks
D6 - Implement and ValidatePermanent Corrective Actions
Plan and implement selected PCAs
Validate that PCAs are continuing to work
D7 - Prevent Recurrence Find the root cause of
the root cause Change the systems
that allowed the problem to occur
D7 - Prevent Actions
Present Problem Similar Problems Systemic
Recommendations
Champion
D8 - Recognize Team and Individual Contributions
Sincerely recognize all contributions to solving the problem
Celebrate Formally close the
G8D
How to Ensure Success & Increase ROI
l Create the right climate
l Identify and set the priority of problems
l Support the problem solving process
l Provide the system to carry out corrective actions
Management Createsthe Right Climate
Patience Provide practice time Be interested State expectations clearly
Management Sets the Priorities
Continuously improve the system Provide the right resources Share significance of the problem with the
team
Management SupportsProblem Solving
Give authority to team members Review progress and ask coaching
questions (Assessing Questions) Require adherence to the process
Management is Visible in Implementation
Be an implementation advocate Provide system to retain knowledge Provide funds to follow through