G8D _ Problem Solving Tool in Quality

G8D - Problem Solving Tool in Quality 

Everyone is aware about 8D, but you know what is G8D?

G Stands for Global,

8D stands for 8 Disciplines.

More about G8D - 

In the late 1990s, Ford developed a revised version of the 8D process that they call "Global 8D" (G8D), which is the current global standard for Ford and many other companies in the automotive industries.

8D has 8 steps & G8D has 9 steps, 

G8D Steps are - 

D0 - Emergency response actions - 

This is an instant act against the reported customer complaint to avoid the customer line stoppages. One from supplier should visit at customer end immediately. Quality alert should display at respective manufacturing lines to aware those who is working & taking care of that particular product.

D1 - Define a cross function team 

CFT is group of people with different functional expertise. When you are solving a problem of product quality, CFT includes one from manufacturing, one from quality, process experts / manufacturing engineering, maintenance and other expertise those are well educated about the manufacturing process.

D2 - Problem Description

While describing the problem - use '5Ws' & '1H'. 

1. Who  is it about?
2. What  happened?
3. When  did it take place?
4. Where  did it take place?
5. Why  did it happen?
6. How  did it happen?

D3 - Interim Containment Actions 

Steps to be followed for containment actions - 

1. Check & inspect all parts which are available at customer end & provide good parts to customer's manufacturing lines.

2. Check & inspect all parts at warehouse, check parts are in transit.

3. Check & inspect all parts which are available at your end, check ongoing productions too.

Note - There should be an evidence mark of containment action on each & every inspected part to ensure the supply of good parts to customer lines. Customer quality representative should inform customer regards to the containment mark & batch code of good parts.

D4 - Root Cause Identification 

Best tools to find out root cause -

Ishikawa / cause & effect diagram & 5 why analysis.

Ishikawa Diagram

Ishikawa diagrams (also called fishbone diagrams & cause-and-effect diagrams) are useful to find out the possible/potential causes of the specific defect. 

After getting the the possible causes, do the validation of each cause & find out, how many of them are contributing to generate & pass that bad product to customer.

Do "5 why" analysis for each contributing possible cause - 

Example - 

D5 - Determine corrective actions 

Choose corrective action that will address the problem permanently. Action should take place for occurrence and detection.

Actions on occurrence is to prevent the defect before it produces.

Actions on detection is to catch the defect before it reaches to customer.

D6 - Implement & validate permanent corrective actions 

Validation of corrective action is top most important aspect in the 8D. Sometimes actions are not effective, sometimes bad product may get produced or may get passed to customer. Do the negative validation, try to produce the bad product after implementing corrective actions.

D7 - Prevent recurrence / system problems 

Corrective action prevents the recurrence & preventive action prevents the occurrence of the defect. Management systems, Control Plan, PFMEA, Work instructions, Quality Tips & other documents must be updated in D7.

D8 - Horizontal Deployment / Congratulate the Team.

Provide recognition to CFT as well as CFT should consider same actions as a horizontal deployments to other products if applicable. 

8D report Format - 

 Thank You...