Global8DProcessTrainManual

1、global 8d process d1 establish the team the purpose of the d1 is to 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 problems and implement corrective actions. the group must have a de

2、signated champion and team leader. the group initiates the team building process. team membership the problem cannot be solved by one person. the members must have the different technical skills required to solve the problem. the team membership should be limited to between four and ten members. the

3、 membership can change according to the stage within the process. team roles champion : ?have ownership of the system or process under consideration ?have authority to make changes ?make resources available to the team ?support team decisions ?use appropriate questions to monitor the teams progress

4、?attend meetings, if required ?create an environment for empowerment of team notes: _ _ _ _ global 8d processleader ?the teams business manager ?the spokesperson for the team ?work with the team to set objectives and tasks ?ask for and summarize members opinions ?direct the use of the global 8 d pro

5、cess ?summarize decisions ?form a sub team with a scribe and facilitator ?explicitly give up the leadership role when participating in discussion team member ?provide technical input ?carry out assignments ?offer information and ideas ?provide feedback ?clarify issues ?participate scribe ?record the

6、 leaders summary ?restate and records team decisions during meetings ?make team decisions visible notes: _ _ _ _ global 8d processfacilitator ?ensure that all members have the opportunity to contribute ?focus on how the team is working together ?give and ask for descriptive feedback ?suggest process

7、 and maintenance checks ?act as a team builder ?focus on team maintenance ?draw attention to communication skills ?ensure the team starts and finishes effectively ?helps team members to increase awareness of other team members and the team environment guidelines for implementation of roles ?with the

8、 exception of the champion, adoption of these roles assists a team in any discussion meeting. they are not adopted for talks or a session given purely to gather information. ?roles are not people. roles are functions that people fulfill. ?members are often given roles for the duration of the meeting

9、 or the duration of the team process. ?confusion can rise when team members exchange roles in the middle of the meeting. ?when the leader offers an opinion, he or she automatically leaves their role as leader. notes: _ _ _ _ global 8d process?if this is not done overtly, the team will be leaderless

10、until someone notices and takes up the role. meetings then become longer. ?the same is true for the facilitator and the scribe. ?role changes mid-meeting need not be disruptive if they are made overtly so everyone on the team is aware. ?some process-oriented roles can be shared. ?leadership and faci

11、litation are very difficult to share, the leaders role must stay continue to follow the problem solving methodology ?facilitation is essential throughout the process. this means one person is not participating directly in the problem solving task. when all the team members have acquired the skill of

12、 facilitation, the role is adopted by the person who potentially has the least input. ?supervision speeds the ability to learn these roles at any given moment. notes: _ _ _ _ _ _ global 8d processd2 problem statement ?a problem statement is a simple, concise statement that identifies the object and

13、the defect of a problem for which the cause is unknown. ?the problem statement is derived by using the process question: ?what is wrong with what? and testing it with 5 whys rationale for the problem statement ?the purpose of the problem statement is to ?keep the team focused ?narrow the search for

14、the root cause ?serve as a starting point for the problem description ?the problem description is the output of a process used to amplify the problem statement in terms of what, where, how big (is, is not method) ?the problem description data provides the basis for testing the cause of the problem.

15、developing a problem statement - step 1 ?first step: what is wrong with what? ?what is wrong . . . if the defect?the defect is an unwanted condition or characteristic present in a product or process.?. with what? is the object.?the object is the name given to a specific product or process that exhib

16、its the defect.developing a problem statement - step 2 ?once the object and defect are established, the second step in the process is to ask, why is that happening to that object? global 8d process ?redefine the statement to ?focus efforts on a single problem with a single root cause ?get as near as

17、 possible to the root cause using existing data ?check that the cause of the problem is unknown. the process of asking, why is that happening to that object? over and over again is the 5 why method the team continues asking the question, why? until the question cannot be answered with certainty. if

18、the cause is unknown and there is a need to find the root cause, then the last object and defect with an unknown cause is the problem statement. notes: _ _ _ _ _ _global 8d process d3 develop the interim containment action d3 purpose ?the purpose of d3 is to define, verify and implement the interim

19、containment action to isolate the effects of the problem from any internal/external customer until permanent corrective actions are implemented. it is also the purpose of d3 to validate the effectiveness of the containment action. rationale the rationale for d3 is to ? buy time to solve the root cau

20、se of the problem ? protect the customer from the effect of the problem ? contain the problem from a cost, quality, timing perspective temporary, works against the effect or problem. an action that prevents the symptoms of one or more problems from being experienced by internal/external customers. a

21、n interim containment action is an emergency response action. ?attacks the symptom - problem ?is verified for effectiveness before implementation ?is monitored while being used ?is documented ?is replaced by permanent corrective action at d6. ?adds costs verificationproof developed before implementa

22、tion that the action will do what is intended by providing a before and after data comparison; it does not introduce a new problem. tests and demonstrations 1. an example would be an added visual inspection at the point of the process where the defect occurs.global 8d process 2. another example, if

23、the complaint is a missing roller, we could add a step to the process that checks for rollers.key concept: these actions are detection, our goal of the global 8d process is prevention. comparison of the new action with a similar proven action 1. an example would be the use of a new cutting oil in th

24、e cup dept. that improved part finish while increasing tool life is introduced into the cone dept. which has a similar process . reviews of newly designed documents before their release ?all documents (procedures, control plans, fmeas, specifications, etc.) require review for accuracy before their r

25、elease. verification, however, requires a process that evaluates the ability of the change to accomplish what was intended without introducing a new problem. ?trial runs are recommended whenever possible. ?verification could be achieved by establishing a cross-functional team to evaluate the change.

26、 a pilot might be conducted to better study the effects of the changes. ultimately, team consensus should be obtained. validation ongoing evidence that the implementation action is doing what was intended without introducing a new problem. validation follows successful verification. an example of va

27、lidation could be through internal audits. although the customer is the final check for validation, discretion dictates that the customer is not the primary way to validate the change. an example would be, repeat complaints, or the fact there are no complaints, is not validation. global 8d process p

28、re-customer validation ongoing evidence (data) - before exposure to the customer and following successful verification - that the implementation action is still doing what was intended without introducing a new problem. validation activities may include tests, inspections, observations and other qua

29、lity checks performed on production product using the specified production process. these checks are correlated to the customers symptom and are good indicators of action effectiveness. customer validation ongoing evidence (data) - received from the customer - that the action taken to eliminate the

30、customers symptom is still working. confirmation is obtained by monitoring the same indicator that demonstrated the symptom initially. notes: _ _ _ _ _ _ global 8d processd4 define and verify root cause and escape point the purpose and function of d4 are to: ?isolate and verify the root cause by tes

31、ting each root cause theory against the problem description and the test data ?isolate and verify the place in the process where the effect of the root cause could have been detected and contained but was not (the escape point) possible cause any cause, frequently identified on a cause and effect di

32、agram, that describes how an effect may occur most likely cause a theory, based on available data, that best explains the problem description root cause a verified cause that accounts for the problem, verified with data and through testing notes: _ _ _ _ global 8d processd5 choose and verify permane

33、nt corrective actions for root cause and escape point purpose of d5 ?select the best permanent corrective action to remove the root cause ?select the best permanent corrective action to address the escape point ?verify that both decisions will be successful when implemented ?not cause/create undesir

34、able effects permanent corrective action ?fixes a problem at the root-cause level ?generates no additional problems ?has been verified to work - data/testing verificationproof developed before implementation that the action taken will do what do what is intended by providing before and after data co

35、mparison notes: _ _ _ _ global 8d process d6 implement and validate permanent corrective action the purpose of d6 is: 1. to plan and implement selected permanent corrective action; 2. to remove the interim containment action; and 3. monitor long-term results. planning and problem preventionproblem p

36、revention systematically reviews the steps of a plan and asks? ?what could make the step/phase go wrong? ?what needs to be done to prevent that from creating problems? ?what contingent plan should be in place to address the problems? planning 1.state objective 2.identify standards and conditions to

37、be met 3.action plan action plan ?must contain objective, date to be completed and person responsible validation the process of on-going analysis to provide evidence that the implemented action is doing what was intended without introducing a new problem. validation follows verification. notes: _ _

38、_ _ global 8d processd7 prevent recurrence the purpose of d7 is to ?modify the necessary systems - including policies, procedures, control plans, training materials, flow charts - to prevent recurrence of this problem and similar problems. ?make recommendations for systemic improvements, as necessar

39、y review and revise existing documentation ?fmea ?procedures - qs 9000, iso ?process flow ?control plans ?detection methods notes: _ _ _ _ _ _ global 8d processd8 recognize team and individual contributions purpose ?complete the team experience ?sincerely recognize both team and individual contribut

40、ions ?share lessons learned, best practices complete the 8d formal documentation notes: _ _ _ _ _ _ _ _ problem solving worksheetproblem description problem statement: (whats wrong with what)problem description isis notget information object defect first seen problem solving worksheetcomparative ana

41、lysis differences changes dates problem solving worksheetroot cause theories a. b. c. d. e. f. g. is/is not matrix job aid - questions to ask to complete the matrix is is not what: name the object that is defective what: name the objects, similar in shape, composition, form or function this could be defective, but is not name the defect or problem that the object is having name other kinds defects this object could be experiencing, but is not. where: name the pla