Ford Global 8D Process

1、global 8d process executive overview presented by: mohamed o. ezzat ptp 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 oppo

2、rtunity? “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 proble

3、ms. symptom real problem background of g8d g8d is the result of combining the best-practices of several methodologies global 8d defined a disciplined, systematic process for solving problems and preventing their recurrence global 8d functions problem-solving process global 8d functions problem-solvi

4、ng 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 cor

5、rective actions implement & validate permanent corrective actions prevent recurrence recognize team & individual contributions why ford developed g8d best allocation of time cost of resolving problems actual time spent past problem solving low 3 - 5 x 80% present decision making medium x 10% future

6、planning high .1 x ? 10% focus of g8d steps problem solving decision making planning and prevention d2 d4 d0, d1, d3, d5, d8 d6 d7 inhibitors to effective problem solving jumping to conclusions bias lack of factual data no logical process impatience failure to use corrective actions etc. g8d highlig

7、hts 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 of performance time expectation “something changed gradually” actual change-induced vs. never

8、-been-there situations level of performance time “something changed abruptly” expectation actual change-induced vs. never-been-there situations level of performance time “never-been-there” desired actual addressing alternative problems lchange-induced conditions lmultiple cause ford suppliers and g8

9、d 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

10、 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

11、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 - de

12、scribe the problem lproblem statement n“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

13、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 verify root cause and escape point test each possible cause against

14、 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 problem problem d4 - escape point the

15、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 ldecision-making workshee

16、t decision making worksheet givens choice a choice b wants risks d6 - implement and validate permanent 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 pro

17、blem 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 lcreate the right

18、climate lidentify and set the priority of problems lsupport the problem solving process lprovide the system to carry out corrective actions management creates the 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 s