G8D Guidelines

G8D Process Objectives

Illustration
 G8D Process
 Problem solving process
 A standard that commits to solving problems at root
cause level and preventing the problem from
happening again
 A reporting format that describes the team's
progress at each step
 Rational approach - Promotes use of facts and
figures
 "If you can't prove it, you should not say"
 People oriented approach
 Use the experience of those who do the work
 Creative approach
 Dismantle the satus quo
 Brainstorming
 G8D Process

 Symptom complexity exceeds the ability of one

person to resolve the problem
 To prevent customer from adverse effects of the
problem
 Supplementary tools
 Benchmarking
 Cause and effect diagram
 Critical path method
 Pareto chart
 Brainstorming
 Action plan
 Objectives
D0 Symptom
As per symptom, provide Emergency Response Action to
protect the customer
Initiate the G8D process

D1 Team
Small group
Product/process knowledge
Team leader
Team synergy

D2 Describe the problem

" What is wrong with what"
Describe the problem in quantifiable terms
Use only one G8D per problem
 Objectives cntd...

D3 Interim Containment Action (ICA)

Implement ICA to isolate the effects of problem until PCA
Formal temporary Fix
Validate effectiveness
Optional step
"Buy Time" to solve the root cause of the problem
Contain the problem from a cost, quality, timing perspective
Works against the problem, not the root cause
Increases costs while the ICA is used.
 Objectives cntd...

D4 Root cause/escape point

Identify the root cause
Cause and effect diagram
Potential root cause list
The single verified reason that accounts for the problem
Escape point
The earliest location in the process, where the problem
should have been detected, but was not
Problem solving step
 Objectives cntd...

D5 Chosen Permanent Corrective Action

Making the best decision, based on benefits and risks
Verify that the choice will work
Not rushing into implementation
More than one PCA may be required to resolve 100% of the
problem

D6 Implement Permanent Corrective Action (PCA)

Remove ICA
Implement decision made at D5
Cross functional participation
Update all the documents, procedures etc
Train the workforce
Seek feedback from the customer
 Objectives
D7 Prevent recurrence
Modify necessary systems (Practices/Procedures) to prevent
recurrence of
this problem or a similar problem
The goal is to change the system that allowed the problem to
occur in the first place
Enables lessons learned can be shared
Conserves resources by saving rework on other problems

D8 Recognize Team
Complete the team experience
Sincerely recognize both team and individual contributions
Encourage a repeat of the behavior
 G8D Report-Illustration
Title Date Opened Last Updated
Multi model part shipment. 12-10-2001 15-10-2001
Product/Process Information Organization Information
Receiving Process TVSLL-KDPP
Dø Symptom(s) Multi model part was shipped as Sea
Dø Emergency Response Action(s) % Effective Date Implemented
1.            Intimated SCM 100% 12-10-2001
2.            Reversal of SEA shipment.
D1 Team (Name, Profs, Dept., Phone) D2 Problem Description
Champion: Prasad, M P&L Multi-model part no XS61-18K579-DC 180 nos shipped in Sea
Team Leader: Arunachalam container instead of multi-model shipment
Team Members:
Sampath - MP&L analyst
Hemanth - Receiving Analyst
Parthasarathy - Receiving Checker
D3 Interim Containment Action(s) % Effective Date Implemented
Followed up with SCM and diverted material 100% 12-10-2001
from Main Plant.
D4 Root Cause(s) % Contribution
Lack of Process control measure affected receiving checker's ability to concentrate 100%
D5 Chosen Permanent Corrective Action(s) % Effective
1.       Different receiving color tags for multi model shipment parts.
2.       Receiving Flag will be raised in CMMS3 by MP&L analyst 100%
3.       MP&L analyst will track the multi model parts
D6 Implemented Permanent Corrective Action(s) Date Implemented
1.       Different receiving color tags for multi model shipment parts.
2.       Receiving Flag will be raised in CMMS3 by MP&L analyst
3.       MP&L analyst will track the multi model parts 15-10-2001
D7 Prevent Recurrence Date Implemented
1.            Regular awareness training.
2.       Multi model shipment information to consolidators. 15-10-2001
D7 Systemic Prevent recommendations Responsibility
Multi model shipment part labels to be color coded by supplier MH&PE
D8 Team and Individual Recognition Date Closed Reported By
Personally thanked all the team members 15-10-2001 A.Arunachalam
THANK YOU