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1、D1D2D3D4D5D6D7D8DWELCOME TO GLOBAL 8D/7/30/2024Slide #1-1Jul-241Who are YOU?Exercise No. 110 MinutesExercise # 1*/7/30/20242Care To Share?Exercise No. 1lPick a Partner - Conduct an interview.lWrite down your partners name!What does he/she doing?lTell us more about your partner:one thing your partner
2、 enjoys doing!one skill your partner masters!what does your partner do for fun?lWhat does he/she expect out of this workshop?10 MinutesExercise # 1*/7/30/20243Introduction - Exercise No. 1DebriefingIntroduce your partner to the GroupExercise # 13 Minutes*/7/30/20244The Purpose ofThe WorkshopProvide
3、you with:lThe basic tools and knowledge needed to complete the G8D process as an active team memberlAn opportunity to practice using the tools in a case study.*/7/30/20245Learning OutcomeslWhen you complete this workshop, you will be able to:describe the purpose and benefits of key Global 8D problem
4、-solving tools at each stepuse assessing questions effectively at each stepcomplete the problem description at D2complete root cause analysis at D4complete a Global 8D reportJul-246Workshop MaterialsG8DParticipantGuideYellow Job AidsJul-247A Journey Through The ProcesslG8D ProcesslParticipants Guide
5、lG8D Study Folder & Report*/7/30/20248Day 1 AgendalD - Prepare for the Global 8D ProcesslD1 - Establish the TeamlD2 - Describe the ProblemlD3 Interim Containment ActionlD4 Root Cause & Escape PointJul-249Three Types of Problem-Solving ApproacheslRational uFact basedlExperiential (People) uTeamsuEmpl
6、oyee InvolvementlCreativeuBrainstormingG8D Uses ALLJul-2410Global 8D ApproachlUse of Emergency Response Action (ERA)Formalized tracking, verification and validation of Containment Actions to protect customerslImplementation of G8D Application criteria lIntegrate Process Improvement & Problem Solving
7、lStandardized use of termsNever-Been-There (Common Cause) conditionsChange-induced (Assignable Cause) conditionsEscape pointsVerification & ValidationJul-2411Prepare for the Global 8D ProcessDD1D2D3D4D5D6D7D8/7/30/2024Slide #1-12Jul-2412D PurposelEvaluate the need for the G8D processlProvide “Emerge
8、ncy Response Action”, if neededJul-2413D Session ObjectiveslYou will be able to determine whether or not to use the full G8D process to solve a problem based on the application criteriadescribe the common tasks that may occur at each step of the G8D processdescribe how to use the G8D assessing quest
9、ionsJul-2414Key ConceptsJul-2415Key ConceptsUnwanted EffectJul-2416Key Concepts - ERAJul-2417Trend (Run) ChartActualExpectedWeek 1 Week 2 Week 3 Week 4RevenueQuantifying the SymptomsJul-2418Pareto ChartQuantifying the SymptomsJul-2419Paynter ChartINCIDENTS PER MONTHE=Emergency Response Action (ERA)I
10、=Interim Containment Action (ICA) I1=First ICA I2=Second ICA etc.P=Permanent Corrective Action (PCA)CUSTOMER PROBLEMCLASSIFICATIONS1. Take off: Accidents2. Landing Accidents3. Groundstation Failure4. Lost Communications5. Power Failure6. Unexplained Crashes7. Explained Crashes8. Lost Signal Crashes3
11、14310006815000304001012PROTOTYPE DEVELOPMENT000000P0000000005206101612613101344010002110110020000000100000I000000000011000001PPPP14231501110304021312345678 Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep YTD TOTALSFirst Customer DeliveryProduction BeginsPPRODUCTION RUNQuantifying the SymptomsJul
12、-2420D Tools SummarylTrend Chart - displays performance over timelPareto Chart - shows ranking based on frequencylPaynter Chart - shows effectiveness of corrective actionsJul-2421Trend, Pareto and Paynter ChartsEscort Instrument PanelContdJul-2422Trend, Pareto and Paynter ChartsEscort Instrument Pan
13、elPARETO CHARTSource: 1 MIS Warranty Claims - MYTDEscort Instrument PanelContdJul-2423Trend, Pareto and Paynter ChartsEscort Instrument PanelA - ICAAdd Foam TapeB ICALubricate RailsC ICAFoam Tape Around ConnectorD E PCA(Root Cause)F ICAMylar Tape to IP PCA(EscapeJul-2424DefinitionsG8D customerand af
14、fected partiesJul-2425G8D Application Criteria1.The symptom has been defined and quantified 2.The G8D customer(s) who experienced the symptom(s)-and when appropriate, the affected parties-have been identifiedContdJul-2426G8D Application Criteria (contd)3.Measurements taken to quantify the symptom(s)
15、 demonstrate that a performance gap exists, AND/OR the priority (severity, urgency, growth) of the symptom(s) warrants initiation of the processContdJul-2427G8D Application Criteria (contd)4.The cause is unknown5.Management is committed to dedicate the necessary resources to fix the problem at the r
16、oot cause level and to prevent recurrence6.The complexity of the symptom exceeds the ability of one person to resolve the problemJul-2428Common TasksAt the end of each D Step, Perform theFollowing Tasks:lDocument the changeslReview the team compositionlReview the measurable(s)lUpdate G8D reportJul-2
17、429D SummarylThe purpose of D is to evaluate the need for the G8D process provide Emergency Response Action, if neededlUse the G8D Application Criteria to determine whether to use the G8D processlUse the assessing questions at each step in the G8D process as a formative process check and a confirmat
18、ion of readinessJul-2430Establish the TeamD1DD2D3D4D5D6D7D8/7/30/2024Slide #1-31Jul-2431D1 PurposelTo establish a small group of people with the process and/or product knowledge, allocated time, authority, and skills in the required technical disciplines to solve the problem through identifying the
19、root cause and implementing corrective actionslTo designate Champion and Team LeaderlTo begin the team-building processJul-2432Group vs TeamlGroup.Any number of individuals with a common goal, working independently w/o interactionlTeam. Any number of individuals with a common goal, working TOGETHER
20、with interdependent and collaborate efforts*/7/30/202433D1 Session ObjectiveslYou will be able to describethe guidelines to determine team membershipteam rolesteam operating proceduresJul-2434Team MembershiplThe problem cannot be solved by one personlThe teamneeds different technical skillsshould ha
21、ve between 4 and 10 membersmembership can changeJul-2435Overview of Team RoleslThe roles are based on functionchampion team memberleadertime managerscriberecorderfacilitatorJul-2436Guidelines for Implementation of RolesJul-2437Team Operating ProcedureslEstablish ground rules for teamworklConduct tas
22、k, maintenance, process observationlUse your speaking skillsJul-2438Ground Rules for Team WorklStart and finish on timelQuickly select roleslKeep work visiblelHelp leaderlOtherJul-2439Phases of Team MeetingContdTaskJul-2440Phases of Team MeetingTaskMaintenanceContdJul-2441TaskProcessObservationMaint
23、enancePhases of Team MeetingJul-2442Speaking Skills GuidelinesJul-2443The Team System ModelINPUTOUTPUTPROCESSJul-2444Team SynergyJul-2445Establish the Team Exercise No. 2Exercise # 220 MinutesJul-2446 Establish the Team Instructions lWarm Up - get to know your teamlDecide on team roleslEstablish tea
24、m ground rulesExercise # 320 MinutesJul-2447Establish the TeamDebriefinglTeams Name!lRoles (Team Leader, Time Manager, etc.)lGround RuleslSimilarities?lDifferences?lConstraints?Exercise # 320 Minutes*/7/30/202448D1 SummarylTeam membershiplTeam roles lOperating procedures lTeam system model lTeam syn
25、ergyJul-2449Describe the ProblemD2DD1D3D4D5D6D7D8/7/30/2024Slide #1-50Jul-2450Exercise No. 3“Tell Me What the Problem Is”Exercise # 35 MinutesJul-2451“Tell Me What the Problem Is?” InstructionslRead “Tell Me What the Problem Is” ahead in the Participants GuidelWrite down what you think the problem i
26、s lTime: 5 minutesExercise # 35 MinutesJul-2452D2 PurposelTo describe the internal/external customer problem by identifying “what is wrong with what” detailing the problem in quantifiable termsJul-2453D2 FunctionlIdentify the object and the defectlAct as a database for describing the problemlDefine
27、the problem as accurately as possiblelDrive the rest of the G8D processJul-2454D2 Session ObjectiveslYou will be able toexplain the process for describing a problemdevelop a problem statementdevelop a problem descriptionJul-2455Key ConceptslA problem statement isa simple, concise statement that iden
28、tifies the object and defect of a problem for which the cause is unknown derived by using the process question Whats wrong with what? and testing it with Repeated WhysJul-2456Global 8D TerminologySymptomSymptomSymptomVoice of the CustomerProblemProblemProblemProblemJul-2457Problem StatementStair Ste
29、pping MethodWhy?Why?Why?Why?Why?Why?*/7/30/202458DemonstartionlEngine knockinglPM Program*/7/30/202459Rationale for the Problem StatementlKeeps the team focusedlNarrows the search for the root causelServes as a starting point for the problem descriptionlDefines what problem you want to find the root
30、 cause forJul-2460Key ConceptslProblem descriptionThe output of a process used to amplify the problem statement Provides the basis for testingJul-2461Developing a Problem StatementStep 1lFirst, identify the object and the defectlThe object and defect are defined by asking “What is wrong with what?”J
31、ul-2462Developing a Problem StatementStep 2Jul-2463Exercise No. 4Developing a Problem StatementExercise # 410 MinutesJul-2464Developing a Problem Statement InstructionsUsing the scenarios provided in your PGwork in teams of twowrite a problem statement for the first scenariobe prepared to report you
32、r resultsmove to the next scenario as directedyou have 2.5 minutes per scenario(Total: 10 minutes)Exercise # 410 MinutesJul-2465Problem Statements Exercise No. 4DebriefinglProblem StatementWhat is Wrong With What?Exercise # 45 Minutes*/7/30/202466Subdivide the SymptomlSubdivide complex, multiple or
33、vague problemsseparateprioritizedeal with one at a timelThe goal is a concise problem statementJul-2467Separating a Generic Symptom Into Multiple Problem StatementslWhy - problem-solving works best on 1 problem at a timelHow -review the dataseparate the problemsprioritize the problemsJul-2468Global
34、8D TerminologySymptomSymptomSymptomVoice of the CustomerProblemProblemProblemProblemProblem StatementObjectRepeated “Whys”DefectJul-2469Problem DescriptionlDefines the boundaries of a problemlNarrows the searchProblem StatementProblem DescriptionJul-2470How to Develop a Problem DescriptionlDescribe
35、the event in terms ofwhatwhere whenhow bigJul-2471Demonstration: Problem DescriptionFelt Tip MarkersJul-2472Exercise No. 5Developing a Problem DescriptionThe Naples Case - D2Jul-2473Problem Description for Naples Case Exercise No. 5Instructions lDecide on team roleslRead the Naples case lUsing the l
36、arge Is/Is Not form, record your teams responses for each area (what, when, where, how big)lTime: 30 minutesExercise # 530 MinutesJul-2474“Naples Case”DebriefinglProblem StatementlProblem DescriptionExercise # 530 Minutes*/7/30/202475Global 8D TerminologySymptomSymptomSymptomVoice of the CustomerPro
37、blemProblemProblemProblemProblem StatementObjectRepeated “Whys”DefectProblem DescriptionIs/Is NotProcess FlowCause & EffectJul-2476D2 Supplemental ToolslSome places to lookProcess Flow Diagram - displays where in the process the problem is occurring Cause & Effect Diagram - identifies the universe o
38、f possible causesJul-2477Summary D2 Supplemental ToolslProblem StatementlProblem DescriptionlProcess Flow DiagramlCause and Effect DiagramJul-2478Other Potential ToolslHelpful tools to collect D2 information or to reference if they already existnonconformance (trouble) reportsdeviation reportspictog
39、rams/check sheetsSPC data/sampling plansrun chartsContdJul-2479Other Potential Tools (contd)scatter diagramsvisual inspection of the object(s)/site inspectionsinternal/external customer surveys/interviews (e.g., binary/process/embedded questions)previous G8D reportsJul-2480D2 Summary Key PointslProblem statement - object and defectlProblem description - the is/is not analysis: what, where, when, how biglSubdivide the problem - deal with one problem statement at a timeJul-2481
