Global 8 Discipline

Agenda-G8D
 Introduction of participant
 Overview of G8D
 Understanding of Discipline D0-D8.
(Example & Case study)
 Summary.
Introduction of participant
Type Of Problem Solving
Approaches
 Rational – Fact & Logical Based
 People Based – Experiential (e.g Team,
employee involvement, participative
management, C&E diagrams.
 Creative-e.g. Brainstorming
 How G8D fit to an Organization
The world
Class
Company

Customer Empowered
Satisfaction Product People
Lower Cost
Excellence

G8D
Overview – G8D
 G8D is a Disciplined process which addresses
problem & problem solving in a methodical and
analytical way.
 G8D process seeks to define and understand a
problem and It provides a mechanism for
identifying root cause and implementing an
appropriate corrective action.
 G8D can also change system, so that the problem
and other problem similar to it are prevented
from happening again.
G8D-Learning Outcomes
 Distinguish between problem and problem
solving methodologies.
 Describe the purpose and function of each
step of G8D.
 Function as active team member.
 Complete the Problem Description at D2.
 Complete Root Cause analysis at D4.
 Complete a G8D report.
Symptom
 A quantifiable event or effect, experienced
by internal or external customers.
 Example:-Field Complaint, Customer
rejection, Warranty cost, Final Inspection
rejection, Process rejection.
Problem
 A deviation from an expectation, a special
cause, high variation, any unwanted effect.
 Example:-Dim Not OK, Material Not OK,
Fitment Not OK, Rust, Capability Not OK.
D0 - Prepare For G8D Process
 Purpose
– In response to a symptom,evaluate the need
for the G8D process.
– If necessary, provide emergency response
action to protect the customer and initiate the
G8D process.
D0 - Prepare For G8D Process
 Application Criteria-G8D
– The symptom has been defined and quantified.
– Who experienced, When it happened and who
affected have been defined.
– Measurement taken to quantify the symptom
demonstrate that a performance gap exist.
– The cause is unknown.
– Management is committed to dedicate the necessary
resources to fix the problem at root cause level &
prevent recurrence.
– Symptom complexity exceeds the ability of one
person to resolve the problem.
D0 - Prepare For G8D Process
 Some common Tools
– Trend Chart
– Pareto Chart
– Check Sheet ( Paynter Chart )
D0 - Prepare For G8D Process-
Exercise Page 78A time 15’
 Identify Symptom.
 Suggest Emergency Response Action.
 Evaluate G8D requirement based on
application criteria.
 IF G8D required fill in G8D form up to D0
D0 - Prepare For G8D Process G8D Report
Title Date Opened Last Updated

Product / Process Information Organisation Information

D0 Symptom(s)

D0 Emergency Response Action % Effectiveness Date Implemented

Verification / validation
D1 Team ( Name, Dept, Phone ) D2 Problem Statement

Problem Description

D0 Interim Containment Action (s) % Effectiveness Date Implemented

Verification / validation
D4 Root Cause(s) Contribution

Verification
D5 Chosen Permanent Corrective Action(s) % Effective

Verification
D6 Implemented Permanent Corrective Action(s) Date Implemented
D1-Establish the Team
 Purpose
– To establish a small group of people (4 to 10)
with the process/product knowledge,
Allocated time, Authority, and skill in the
required technical discipline to solve the
problem and implement the corrective action.
– The group must have Team leader
– The group initiates the team building process.
D1-Establish the Team
 Objective
– You will be able to describe
 The guidelines for determining team membership
 Team role

 Team Operating procedure

D1-Establish the Team
 Function of the team role
– Leader
– Facilitating
– Time managing
– Scribing
– Recording
D1-Establish the Team –
Exercise time 10’
 Decide on team roles
 List your team’s ground rules.
 List what data you need to gather about the
problem.
 Fill in G8D format.
D2-Describe the problem -
Purpose
 Describe the internal / external problem by
– Identifying “What is wrong with What”
– Detailing the problem in quantifiable terms
D2-Describe the problem -
Function
 Identify the object and the defect
 Act as a database for describing the
problem
 Define the problem as accurately as
possible
 Drive the rest of the G8D process
D2-Describe the problem -
Objectives
 Describe the process for describing the
problem.
 Practice developing a problem statement.
 Practice developing a problem description.
D2-Describe the problem -
Remember
Any vagueness or inaccuracy can lead the
team to the wrong cause, followed by the
wrong corrective action.
D2-Describe the problem - Step
 1- Developing Problem Statement
 2- Developing Problem Description
D2-Describe the problem –
Developing Problem
Statement.
– Purpose
 Keep the team focused
 Narrow the search for the root cause

 Serve as a starting point for the problem

description.
D2- Developing Problem
Statement - Exercise Page 78A
time 5’
 Identify the object and defect.
 The object is the name given to the product
or process.
 The defect is the unwanted characteristic
present on a product or process.
 Answering “What is wrong with what?”
identifies the specific object and defect for
which you want to know the root cause.
D2- Developing Problem
Statement - Exercise Page 78A
 ASK: “What is wrong with what?”
 ASK NEXT: “Do we know why this is
happening?”
 IF the answer is “No” the answer to. “What is
wrong with what” is your problem statement.
 IF the answer is “Yes” repeat the question, “What
is wrong with what” until reaching the statement
the cause is unknown.
 Fill in G8D format
D2-Describe the problem –
Developing problem description
 The problem description is the output of a
process used to amplify the problem
statement in terms of what, where, when,
how big ( Is / Is Not method)
 The problem description data provides the
basis for testing root cause of the problem.
D2- Exercise for Developing
Problem description
 Purpose
– To practice the technique for the Is / Is Not portion of
the problem solving work sheet
 Key to remember
– Review the problem statement.
– The first two columns of the problem-Solving work
sheet describe the problem in terms of what, where,
when and how big.
– All Is / Is Not data must be fact.
– All Is / Is not information should be similar in
category, shape, function, form and composition
D3-Develop the interim
Containment Action - Purpose
 Define, verify and implement the interim
containment action to isolate the effects of
the problem from any internal and external
customer until permanent corrective action
are implemented.
 It is also validate the effectiveness of the
containment action.
D3-Develop the interim
Containment Action - Rationale
 “Buy Time” to solve the root cause of the
problem
 Protect the customer from the effect of the
problem
 Contain the problem from a cost, quality &
timing prospective.
D3-Develop the interim
Containment Action - Objective
 You will able to distinguish between
verification and validation.
D3-Develop the interim
Containment Action – Key
Concept
 Temporary works against the effect or problem.
 An action that prevent the symptoms of one or
more problem.
 ICA usually provides the opportunity for more
investigation.
 An ICA may derived from an Emergency action.
 Attack the symptom not root cause.
 Is verified for effectiveness before
implementation.
 Is not a “band Aid” which may forgotten.
 Adds cost.
 Is replaced by permanent corrective action.
D3-Develop the interim
Containment Action –
Verification ( Short term )
 Proof developed before implementation
that the action do what is intended by
providing before and after comparison.
 It does not introduce a new problem.
D3-Develop the interim
Containment Action –
Verification
1.
method
Test and demonstrations
1. 1 An example would be an engine dynamometer test
to verify that a change an engine component’s
design achieved the desired performance level.
2. Comparisons of the new action with a similar
proven action.
1. An example would be the use of a new cutting oil in
a process that improved part surface finish.
D3-Develop the interim
Containment Action – Validation
( Long term )
 Ongoing evidence that the implemented
action doing what was intended without
introducing a new problem.
D3-Develop the interim
Containment Action – Validation
Method
 Pre-customer validation - Ongoing
evidence (data) that the implemented
action doing what was intended without
introducing a new problem.
– Example- Test, inspection, observation and
other quality checks.
 Customer Validation - Ongoing evidence
(data) received from the customer.
D4-Define and verify root cause
and escape point
 Purpose
– Isolate and verify the root cause by testing
each cause theory
– Isolate and verify the place in the process
where the effect of the root cause could have
been detected but was not ( Escape Point)
D4-Define and verify root cause
and escape point
 Objectives
– You will able to describe how to
 Use the problem solving process and its work sheet
to identify the most likely cause of a problem.
 Identify the escape point of a problem.

 Verify the root cause and escape point of a

problem
D4-Define and verify root cause
 Terminology related root cause
– Possible cause – any cause frequently
identified for the problem.
– Most likely cause- 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 problem come and go. ( Switch On
Off)
D4-Define and verify root cause
 Problem Solving Work Sheet
– Review IS / IS NOT (Problem Statement and
Problem description) update if required
– Comparative analysis
– Root cause theories
– Trial run of root cause theories
D4-Define and verify root cause
- Review of IS / IS NOT work
sheet
 Review the problem statement.
 The first two columns of the problem-
Solving work sheet describe the problem
in terms of what, where, when and how
big.
 All Is / Is Not data must be fact.
 All Is / Is not information should be
similar in category, shape, function, form
and composition
 D4-Define and verify root cause
- Exercise Comparative
Analysis.

Root Cause IS IS Not

D4-Define and verify root cause
- Exercise Page 113
 Comparative Analysis.
– List differences / uncommon (Compare the IS
with its corresponding IS not )
 Ask:- What is unique, Peculiar, different,
distinctive, unusual about IS.
 Consider :- People, method, material, machine and
environment.
– List changes in differences
 Ask:- What has changed in, on, around or about
this difference
D4-Define and verify root cause
- Exercise
D4-Define and verify root cause
- Exercise
 Develop root cause theory based on the
changes.
– ASK:- In what ways might changes the defect
on the object?
• OR
– ASK: How could this change create the defect
on the object?
D4-Define and verify root cause
- Verification
 Passive Verification
 Active verification
D4-Define and verify root cause
- Verification
 Passive Verification is done by
observation
– With passive verification. You look for the
presence of the root cause without changing
anything.
– If you cannot prove the presence of the root
cause variable, then chances are great that this
most likely cause is not the root cause.
D4-Define and verify root cause
- Verification
 Active Verification is a process where
– The problem solver uses the variable thought
to be the root cause to make the effect come
and go (Switch on Off).
– Both coming and going are the important tests
to conform root cause.
D4-Define and verify Escape
point
 Where in this process could this root
cause have been detected, but was not?
 The escape point is the earliest location
in the process, closer to the root cause,
where the problem could have been
detected, but was not.
 D5-Choose and verify
Permanent Corrective Action
(PCAs) for Root cause and
Escape
 Purpose
point.
– Select best permanent corrective action to
remove the root cause.
– Select the best permanent corrective action to
address the escape point.
– Verify both decisions will be successful when
implemented.
– Not cause undesirable effects.
D5-Choose and verify
Permanent Corrective Action (
PCAs ) for Root cause and
Escape point.
 Rationale
– Making the best decision, based on benefits
and risks.
– Not rushing into implementation.
D5-Choose and verify
Permanent Corrective Action (
PCAs ) for Root cause and
Escape point.
 Objectives
– You will able to describe the basic styles and
steps in decision making
– You will able to identify the G8D process
criteria for Permanent Corrective Action
(PCAs)
D5-Choose Permanent
Corrective Action
 Criteria
– Fixes a problem at the root cause level
– Generates no additional problem
– Has been verified to work.
D5-Choose Permanent
Corrective Action
 Types
– Unilateral – ( eg. Boss making decision )
 May affect large number of people
– Polling – (eg. Vote in which majority wins.)
 It exclude as well as include.
– Prioritization – (eg. FMEA, QFD)
 Based upon the nature of the situation
– Compromise – (eg. In families)
 Can reduce the conflict
– Consensus –
 Agreement of all team members “ 70% approval, 100%
support.”
D5-Choose Permanent
Corrective Action
 Steps
– Describe the end result.
– List the decision criteria.
 Given ( Essential )
 Wants ( Important )
– Decide on the relative important wants.
– Identify choices.
– Compare choices against decision criteria.
– Analyze the risk.
– Make a final balances choice.
D5-Choose Permanent
Corrective Action
 Describe the end result.
– The end result is a brief statement that
describe the desired end result of the decision.
– The end result is identified in order to define
the scope of the decision and provide a focus
for your thinking.
– Describe the end result by identifying an
action and an objective.
D5-Choose Permanent
Corrective Action
 Describe the end result. - Example.
– Buy a computer system,Machine, Equipment
– Choose an administrative assistant
– Select a supplier.
D5-Choose Permanent
Corrective Action
 List the decision criteria – Givens (
Essential)
– Givens are objectively measurable,
nonnegotiable, realistic features of the
decision.
– Given are the minimum criteria
 It must be Mandatory, objectively measurable,
Realistic.
D5-Choose Permanent
Corrective Action
 List the decision criteria – Givens.
Examples
 Money (eg. Not to exceed budget limit)
 Deadline (eg. Meet Project time )

 Company Procedure (eg.Machine capability,

 Legislation (eg. Any Government regulation)

 Any other mandatory requirements

D5-Choose Permanent
Corrective Action
 List the decision criteria – Wants (
Important )
– Wants are the desirable features of the
decision.
– Wants enable you to determine which of the
remaining choices are preferable
 DECISION MAKING WORK SHEET 1 OF 3

END RESULT: Select a Supplier for casting machining

CRITERIA

GIVENS: (Mandatory, Measurable, Realistic)

a. Cost must be lower than existing supplier

b. ISO 9000 certified

c. PPAP to be completed within 6 months from now.

d.

e.

HOW
IMPORTANT
WANTS: (Objective or Subjective) ( 1-10 )
a. Near to casting supplier
10

b. QS 9000 certification plan

9

c. Positive attitude
7

d. Financially sound
8

e. Good gauging facilitty

6

f. Air connectivity
3

g. Historical PPM must be low

5

h. Historical Delivery must be good

4