G8D - Global 8D Method

Introduction

The Global 8D problem-solving method, created by Ford Motor Company, is a systematic approach to identifying, correcting, and eliminating recurring problems. The methodology is advantageous when dealing with complex issues that require a thorough understanding and resolution to prevent recurrence.

Idea of 8D

Read the 8D Method article to learn about the history of the 8D and its basic idea.

G8D vision and mission

The Global 8D Reference Guide states: "The vision of G8D is to implement a common, worldwide problem-solving process for Ford Motor Company and its suppliers. The mission of G8D is to provide a common process that defines and resolves problems effectively and prevents their recurrence."[1]

G8D Problem Solving Process

The Global 8D method consists of the following dyscyplines[1]:

• D0: Prepare for the Global 8D Process. When a symptom arises, assess whether the G8D process is necessary. Sometimes, a full-scale G8D activity may not be required, and a simple corrective action may be sufficient. If the G8D process is warranted, initiate it. During D0, it may be crucial to implement Emergency Response Actions (ERAs) to protect the customer before proceeding with the G8 process.
• D1: Establish the Team. Assemble a small team of individuals with process and/or product expertise, authority, and the necessary technical skills to solve the problem. Ensure the team has the authority to implement corrective and preventive actions. Appoint a champion and a team leader to guide the team.
• D2: Describe the Problem. Identify what is wrong with what and detail the problem in quantifiable terms by creating a problem description that describes what, where, when, and how big the problem is and is not. Use Is / Is Not with 5W2H.
• D3: Develop Interim Containment Actions (ICAs). Identify, confirm, and implement Interim Containment Actions (ICA) to protect internal and external customers from the impact of the problem until a permanent solution is established. Ensure these measures are effective through validation.
• D4: Define and Verify Root Cause and Escape Point. Identify potential cases of the problem and select the one that most precisely explains the issue. Determine the point in the process where the problem should have been detected and contained but was missed (the escape point). Verify that the selected cause is the problem's true root cause.
• D5: Choose and Verify Permanent Corrective Actions (PCAs) for Root Cause and Reevaluate Escape Point. Identify the most effective Permanent Corrective Action (PCA) to eliminate the root cause's impact. Reassess the escape point while considering the PCA. Ensure that the PCA, when implemented, will be successful and will not lead to any undesirable effects.
• D6: Implement and Validate Permanent Corrective Actions (PCAs). Implement the chosen Permanent Corrective Actions (PCAs) to address the root cause and strengthen the control system at the escape point. Confirm the effectiveness of these measures and continuously monitor their long-term outcomes. Remove ICAs (3D) when PCAs are validated.
• D7: Prevent Recurrence. Review and improve the quality system (policies, procedures, guidelines, etc.) to prevent recurring problems. Document the technical lessons learned.
• D8: Recognize Team and Individual Contributions. Recognize the team's efforts. Share the technical lessons learned. Acknowledge and celebrate the contributions of both the team and individual members and contribute to the project's success.

G8D Report

The G8D report is a document that summarizes the problem-solving process. It contains sections corresponding to each discipline from D0 to D8. The G8D report is often linked to other documents such as analysis and research results, test results, etc.

The G8D report also provides a formal record of the corrective actions taken and is a popular document for communication with the customer or other stakeholders.

Quality tools

When addressing problems, it is helpful to use quality tools such as:

• Check sheet
• Ishikawa diagram
• Control chart
• Histogram
• Pareto chart
• Scatter plot
• Stratification
• Process flow chart

Remarks

You may decide to repair products as part of the activities. In this case, familiarize yourself with the concepts of rework and repair to minimize the risk of misunderstandings with customers or suppliers.

During 7D, it's crucial to review whether the PFMEA analysis or control plan needs updating.

Summary

The G8D method is a great tool for quality improvement. It allows teams to effectively identify root causes and solve problems. An important aspect is to understand the Global 8D method and its differences from other versions of 8D such as "VDA Volume 8D" or "AESQ RM13000."

In my experience, the description of the problem (D2) is crucial for further analysis. Solving incorrectly described problems has cost me a lot of time and resources. I highly recommend using 5W2H, Is/Is-Not tools to better understand the problem.

Root cause identification (D4) is another "hard" discipline. It requires a methodical and open-minded approach, excellent understanding of technical aspects and diagnostic methods. I recommend familiarizing yourself with various methods of root cause analysis.

Understanding and practical application of the G8D method is not only important, but even crucial to the successful work of an engineer.