global 8d process

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


Level ofPerformance

Time

Something Changed Abruptly

Expectation

Actual


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


l Problem Statementn Whats wrong with what?n Why? Why? Why?


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

global 8d process

Documents