The document provides training on the Global 8D (G8D) problem solving approach. G8D is an 8-step systematic approach developed by Ford Motors to solve problems. The 8 steps are: (1) plan to solve the problem, (2) make a team, (3) define the problem, (4) contain the problem, (5) determine the root cause and escape points, (6) verify corrective actions, (7) implement corrective actions, and (8) monitor effectiveness of the actions. The training covers the goals and tools to use at each step of the G8D process, including root cause analysis tools like fishbone diagrams, 5 whys, scatter plots, and control

1. BGPC Quality Assurance
CONFIDENTIAL
Achieving Operational Excellence
using G8D Problem Solving
Approach
April 2016
Henry Tadena Jr
BGPC, Quality Assurance Manager

2. BGPC Quality Assurance
CONFIDENTIAL5
Training: G8D Problem Solving Approach
Mind setting:
Who can tell me what is meaning of a Problem ?
Gap = Problem
Requirement
Reality/ Capability
Specifications
Criteria
Actual
Customer requirement is 1K PMM
BGPC actual is 5K PPM
We have a problem!

3. BGPC Quality Assurance
CONFIDENTIAL
• What is G8D – Global 8D is a Systematic approach of
Solving problem developed by Ford Motors
Training: G8D Problem Solving Approach
D0: Plan to solve the Problem (Know the prequisites)
D1: Make a Team
D2: Define Problem
D3: Containment of the Problem
D4: Root Cause & Escape Points
D5: Verify Corrective Actions
D6: Implement Corrective Actions
D7: Prevent System Problems (Operations, WI, Specs)
D8: Monitor Effectiveness
Plan
Do
Check
& Act
PDCA Cycle
1-day
3-day
15-day
45-day
BGPC Cycletime

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Training: G8D Problem Solving Approach
D0: Plan to
solve the
Problem
(Know the
prequisites)
 What is Scope of the problem
 Product, Lot, Quantity
 What is the impact of the problem
- is it very urgent ?
 What is Failure Rate, λ
 simply: Reject/Input
 When/Where/How it was detected
Talichi Ohno
Inventor of 5-Why analysis

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Training: G8D Problem Solving Approach
D1:
Make a
Team
 Who is right resource person
 Correct team member is very
important
- commitment
- resources
- skills
- authority

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Training: G8D Problem Solving Approach
D2:
Define
Problem
 What is the problem
 Make every member recognize the
problem
- need
- urgency
- effects
- scope

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Training: G8D Problem Solving Approach
D3:
Containment
of the
Problem
 Stop the Bleeding ! NOW !
 Make Immediate action so not to
continue making the same problem
 Tightened Inspection
Example: 100% sorting
Worst scenario:
- HOLD the Lot
- STOP the Line
- Cancel Shipment
- Product Recall
Some Problems can be very expensive!
- example: Tylenol Quality Issue

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Training: G8D Problem Solving Approach
D4:
Root Cause
& Escape
Points
 Brainstorming
 Ask all , ask everything
 Duplicating the problem
Know the data
- Lot history
- Trends
(Yield, Cpk, Control Charts)
Know your Person/Process
- do you have proper person
- do you have enough controls
Know your tools
 Y – Y Analysis
 Fish Bone Diagram
 Pareto / Scatter Diagram
Fault Tree Analysis (FTA)
If you only have a hammer as a tool,
you tend to see every problem as a nail.
- Abraham Maslow

9. BGPC Quality Assurance
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Training: G8D Problem Solving Approach
REMINDER:
1 problem means 2 questions
 What contributes to the problem (Rootcause)
 Why the problem got out (Escapee)
D4: Root Cause & Escape Points

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Training: G8D Problem Solving Approach
Know your Tools : FTA and Y- Y Analysis Combined -- best looking for specific Rootcause!
1st Y
2nd Y
3rd Y
The Problem!
The Rootcause!
Fault Tree Analysis Y-Y Analysis

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Training: G8D Problem Solving Approach
1st Y
2nd Y
3rd Y
The Problem!
The Rootcause!
Fault Tree Analysis Y-Y Analysis
Dents
Inherent
Material
Manual
incident
Method
Problem
Supplier
Outgoing QA
hit the
product
The material
Is easy to
make dent
Subwork
operator hit
with tweezer
The assy
Uses sharp
Tweezer
OQA testing
with
Tweezer
Untrained
Subwork
Operator
Know your Tools : FTA and Y- Y Analysis Combined -- best looking for specific Root cause!

12. BGPC Quality Assurance
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Training: G8D Problem Solving Approach
Know your Tools : Fish Bone (Ishikawa) Diagram – when checking all Possibilities‘
Sometimes called ‘Cause-Effect Diagram
12
3 4
Remember:
All of these can cause bad coffee
But what actually cause bad coffee on that instance?

13. BGPC Quality Assurance
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Training: G8D Problem Solving Approach
Know your Tools : Pareto
80-20 Rule
80% of your
problem is
caused by top
20% defects
After solving
top 20% defect
Significant few
insignificant many
contribution
Defects

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Training: G8D Problem Solving Approach
Know your Tools : Scatter Diagram - to show relation of two variables
Show relation of X and Y
This graph mean most of the
problem occurs
In X (3:4) , Y (15:20)
One can also say
Problem didn’t happen in
X (1), Y (5).
One can also say:
The problem is behaving in linear
regression.

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Training: G8D Problem Solving Approach
Know your Tools : Control Charts
ALWAYS ASK WHY ?

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Training: G8D Problem Solving Approach
D5:
Verify
Corrective
action
 Put you Corrective action into
actual test
Does it working ?
 Use eng’ng time
o Test in the laboratory when
needed
 Make users try to do it themselves
 ask yourself
what is corrective really means?
Corrective actions are action
done when mistake is made
Preventive action are action
needed to be to avoid mistake
(Systemic base)

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Training: G8D Problem Solving Approach
D6:
Implement
Corrective
action
 Implement means to make it
happen every time all the time.
 take note
 implement date
 lot affected
 product affected
 person trained to do the
implementation

18. BGPC Quality Assurance
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Training: G8D Problem Solving Approach
D7:
Prevent System
Problems
(Operations,
WI, Specs
 This is the Preventive action.
 think of things that will make the
problem not happen again
- Update the WI
- Make Poka Yoke jig
- Update the Program
- fan out/ fan in
This is where you don’t allow people
to commit the mistake by making
Error free system as much as you
can!

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Training: G8D Problem Solving Approach
D8:
Monitor
Effectiveness
 Be the Police!
 Establish the System to check
results
- check sheets
- daily trend monitor
- make an index

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Training: G8D Problem Solving Approach
Exercise: Why Titanic sank?

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Training: G8D Problem Solving Approach
Why Titanic sank?
Exercise, 2 minutes
Make quick analysis why Titanic
sank.
If you are the Engineer, what CA can
you propose?
How do you monitor effectiveness?

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Training: G8D Problem Solving Approach
Exercise: Actual Defects in BGPC

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END
Quality has no limit!
5
Training: 8D Problem Solving Approach