You are on page 1of 11

BEGIN PREPARATION FOR G8D PROCESS

Global 8 Discipline Process Proposed by FORD [D0]

Define & Quantify Sympton; Identify Customer and affected parties

Awareness of the Sympton may be Internal or External to the Process

Is an Emergency Response Action (ERA) Required? Yes Determine Appropriate ERA and verify

ERA Verified? No Yes Develop Action Plan, Implement & Validate ERA

No

No ERA Validated? Yes Gather& Review Available Data No

D2A to D0

COMMON G8D TASKS
1. 2. 3. 4. 5. 6. Document the Changes Review Team Composition Review Measurables Determine if Service Action is Required Review Assessing Questions Update the G8D Report

Does the Criteria for G8D Apply? Yes

No

Is there enough Information ? Yes Address Sympton using Other Analytical Methods

Pass the Data to Existing G8D Team

Yes

Will the NEW G8D Duplicate an Existing G8D? No

STOP

STOP

Initiate the G8D Process Involving this Sympton

g8d0 042606.vss

ENDS PREPARATION OF G8D PROCESS

Sympton has been Defined and Meets G8D Application Criteria

BEGIN CREATION OF G8D TEAM

Global 8 Discipline Process Proposed by FORD [D1]
Has Authority to Make Changes & Able to Allocate Resources Responsible for Managing the Team, Directs Decision Making, and is Primary Spokesperson Responsible for Providing Technical or Facilitative Input, Carrying Out Assignments, Offering Feedback, and Clarifying Issues

Identify Champion of System or Process

Identify Team Leader

Selects Team Members Based on Skills and Knowledge Associated with the System or Process

Establish Team Objectives and Membership Responsibilities

Develop Team Procedures and Working Relationships

COMMON G8D TASKS
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

List Team Membership on the G8D Report

g8d1 042606.vsd

CREATION OF G8D TEAM

ENDS

This does not Mean that Membership is Stagnant through out the G8D Process (See Common Task #2.)

G8D Team has been Established

BEGIN DEFINING THE PROBLEM

Global 8 Discipline Process Proposed by FORD [D2]

Review Available Data

D4b to D2

Apply G8D Application Criteria for Each Sympton

Yes

Can Symptom be Subdivided ? No

D2A to D0

State Sympton as an Object and a Defect

Is Cause Known? No Document Problem Statement

Yes

Develop Problem Description (IS / IS NOT)

Identify & Analyze Process Flow Identify Additional Data Required Collect & Analyze Additional Data

COMMON G8D TASKS
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

Does Problem Reflect "Something Changed" Situation? Yes

No

Does Problem Reflect "Never Been There" Situation? Yes

Use Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

Yes

Supplement G8D Process with Improvement Techniques? No Review Problem Description with Customer and Affected Parties via Updated G8D Report

Yes

Use G8D Process?

No Use Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

g8d2 042605.vsd

ENDS DEFINING THE PROBLEM

SUSPEND G8D PROCESS

Problem Description has been Established

BEGIN DEVELOPMENT OF INTERIM CORRECTIVE ACTION (ICA) PROCESS

Global 8 Discipline Process Proposed by FORD [D3]

Evaluate Need to Isolate Effects of the Problem from the Customer UNTIL Permanent Corrective Actions are Implemented

Customers may be Internal or External

Can the Customer Accept the Defect(s)?

Yes

Go To D4

No Eliminate 100% of the Problem from Reaching the Customer Actions must not Create other Problems Downstream Evaluate the D0 Emergency Response Action for Improvement

SUSPEND D3 PROCESS

Identify and Choose the Best Containment Action

ICA Verified? Yes Champion Authorizes ICA Implementation Develop Action Plan, Implement & Validate ICA

No

No ICA Validated?

Yes Document the Actions and Communicate Deployment to Affected Functions

COMMON G8D TASKS
1. 2. 3. 4. 5. 6. Document the Changes Review Team Composition Review Measurables Determine if Service Action is Required Review Assessing Questions Update the G8D Report

Monitor ICA for Continued 100% Effectiveness

g8d3 042606.vsd

ENDS DEVELOPMENT OF ICA PROCESS

Problem Description has been Established and Interim Corrective Action Implemented As Required

BEGIN DEFINE & VERIFY ROOT CAUSE AND ESCAPE POINT PROCESS

Global 8 Discipline Process Proposed by FORD [D4a]

Review & Update the Problem Description As Required

Study the Process; the Inputs, Outputs, & Possible Causes

Possible Tools: Process Flowcharting; Cause & Effect Diagram; Failure Modes Effect Analysis

Evaluate & Verify each Cause on the Possible Cause List

No

Can the Cause Make the Problem Come and Go? Yes Finalize Potential Root Cause List

No

Cannot be Considered as a Potential Root Cause

Is there more than One Potential Root Cause? No Does the Root Cause Account for All Known Data? Yes

Yes

Evaluate the Effects of each Potential Root Cause & Their Interactions

D4a to D4b

Acknowledge the Verified Root Cause & Document on the G8D Report

COMMON G8D TASKS
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

D4b g8d4a 042606.vsd

Root Cause Analysis Resulted in Multple Potential Causes

D4b

Global 8 Discipline Process Proposed by FORD [D4b] D4b to D2 Yes

D4a to D4b

Assign Percent Contribution for each Potential Root Cause

Do the Potential Root Causes Approximate 100% Contribution to the Problem? No Evaluate with the Team Champion the Use of Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

Yes

Do Seperate G8D's need to be Generated for Each Root Cause? No

No Use G8D Process?

Use Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

Yes

SUSPEND G8D PROCESS

Supplement G8D Process with Improvement Techniques? No Acknowledge the Verified Potential Root Cause(s) & Document on the G8D Report

Yes

Use Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

COMMON G8D TASKS
1. 2. 3. 4. 5. 6. Document the Changes Review Team Composition Review Measurables Determine if Service Action is Required Review Assessing Questions Update the G8D Report

g8d4b 042606.vsd

D4c

Root Cause or Potential Root Cause(s) has/have been Defined and Verified

D4c

Global 8 Discipline Process Proposed by FORD [D4c]

Review Process Flow & Identify Control Points for the Root Cause or Each Potential Root Cause

Is the Current Control System Capable of Detecting the Problem? Yes Identify the Control Point Closest to the Root Cause, or Potential Root Cause(s), AND Verify Effectiveness in Detecting the Problem

No

Is the Control Point Capable of detecting the Problem?

No

Acknowledge the Control System as Not Capable AND Needs Corrective Action

Yes Acknowledge the Control Point as Verified Escape Point & Document on the G8D Report

D4c to D5

COMMON G8D TASKS
ENDS PROCESS OF DEFINEING & VERIFYING THE ROOT CAUSE(S) AND ESCAPE POINT
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

g8d4c 042606.vsd

Permanent Corrective Actions for the Root Cause(s) and Escape Point have been Defined

BEGIN CHOOSING & VERIFYING PCAS PROCESS Choose Option in Performing a Decision Analysis

Global 8 Discipline Process Proposed by FORD [D5] Options may be Performed in Series even though Depicted as Parallel Escape Point D4c to D5

Root Cause(s)

Initiate Decision Analysis

D5A Establish Decision Criteria for Root Cause(s) PCA Establish Decision Criteria for Escape Point PCA Ensure that the ICA is Capable for Duration of PCA Implementation

Review Any Data Involving Interim Corrective Actions

Identify Possible Actions, Including ANY Interim Corrective Actions

Identify Possible Actions for Root Cause(s) PCA

Choose the "Best" Permanent Corrective Action

Choose the "Best" Permanent Corrective Action

Verify / "Test" Effectiveness of Root Cause(s) PCA

Verify / "Test" Effectiveness of Escape Point PCA

No

Escape Point PCA Effective? Root Cause(s) PCA Effective? Yes Yes Does Root Cause(s) PCA Affect Verified Escape Point? No

No

Yes D5A

No

No

Has Champion Authorized the Selected PCA? Yes Update G8D Report

COMMON G8D TASKS
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

g8d5 042606.vsd

ENDS CHOOSING & VERIFYING PCAS PROCESS

Permanent Corrective Actions for the Root Cause(s) and Escape Point have been Defined

BEGIN IMPLEMENT & VALIDATE PCAS PROCESS Choose Option in Implementing Permanent Corrective Action

Global 8 Discipline Process Proposed by FORD [D6] Options may be Performed in Series even though Depicted as Parallel Escape Point

Root Cause(s)

Implement Permanent Corrective Action

Develop Action Plan for Implementing Root Cause(s) PCA

Develop Action Plan for Implementing Escape Point PCA

Implement Root Cause(s) PCA per Plan

Implement Escape Point PCA per Plan

Replace ICA with Root Cause(s) PCA AND Evaluate Effectiveness for Escape Point

Replace ANY ICA with Escape Point PCA AND Evaluate Effectiveness at the Escape Point

Yes D5A

Does Root Cause(s) PCA Affect Verified Escape Point? No Perform Validation of the Root Cause(s) PCA No No

Perform Validation of the Escape Point Yes PCA

Permanent Corrective Action(s) Validated?

COMMON G8D TASKS
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

Yes Confirm with Customer that the Symptom has been Eliminated AND Update G8D Report

g8d6 042606.vsd

ENDS IMPLEMENT & VALIDATE PCAS PROCESS

Permanent Corrective Actions for the Root Cause(s) and Escape Point have been Implement & Validated

BEGIN ESTABLISHING ACTIONS TO PREVENT RECURRENCE

Global 8 Discipline Process Proposed by FORD [D7]

Review History of the Problem

COMMON G8D TASKS
Analyze how this Problem Occurred and Escaped Detection
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

Identify Affected Parties & Opportunities for Similar Problems to Occur and Escape Detection D7A Identify the System's Policies, Practices, and Procedures that Allowed this Problem to Occur and Escape to the Customer

Develop Plan to Implement Systemic Actions to Prevent Recurrence

Analyze How the Conditions Above Could Cause Problems Similar to this One

Champion Authorizes Actions to Prevent Recurrence? Yes Implement Systemic Actions to Prevent Recurrence

No

Forward Recommended Actions to Affected Management?

No Go to D8

Are there Possible Prevent Actions that Could Cause Similar Problems? Yes Identify AND Choose Actions to Prevent Recurrence

Yes Go to D8

SUSPEND D7 PROCESS

Validate the Systemic Actions to Prevent Recurrence

SUSPEND D7 PROCESS

Verify Actions to Prevent Recurrence No Systemic Actions to Prevent Recurrence Are Valid? Yes Update G8D Report Yes D7A ENDS PROCESS OF ESTABLISHING ACTIONS TO PREVENT RECURRENCE

Are the Actions to Prevent Recurrence Effective?

No

g8d7 042606.vsd

All Countermeasures for Problem have been Implemented

BEGIN PROCESS OF RECOGNIZING CONTRIBUTIONS

Global 8 Discipline Process Proposed by FORD [D8]

Select Key Documents and Provide for their Retention

Reflect on the Teams Successes & Failures

Document Lessons Learned

Recognize the Collective Efforts of the Entire Team in Solving the Problem

Mutually Recognize the Particular Contributions from each Individual

Celebrate Completion of Problem Solving

COMMON G8D TASKS
1. Document the Changes 2. Review Team Composition 3. Review Measurables 4. Determine if Service Action is Required 5. Review Assessing Questions 6. Update the G8D Report

Update the G8D Report

g8d8 042606.vsd

ENDS PROCESS OF RECOGNIZING CONTRIBUTIONS