BEGIN Global 8 Discipline

PREPARATION FOR G8D Process Proposed

PROCESS by FORD [D0]

Define & Quantify Sympton; Awareness of the

Sympton may be
Identify Customer and Internal or External
affected parties to the Process

Is an
Emergency Response
Action (ERA)
Required?

Yes

Determine Appropriate
ERA and verify

No
ERA Verified?
No
Yes
Develop Action Plan,
Implement & Validate
ERA

No
ERA Validated?

D2A Yes
to
Gather& Review
D0 Available Data
No
COMMON G8D TASKS
1. Document the Changes Is
No
2. Review Team Composition Does the Criteria there enough
3. Review Measurables for G8D Apply? Information
4. Determine if Service Action is Required ?
5. Review Assessing Questions Yes
6. Update the G8D Report Yes
Address Sympton
using Other
Pass the Yes Will the Analytical Methods
Data to Existing NEW G8D Duplicate
G8D Team an Existing
G8D?
STOP
No
STOP Initiate the G8D Process
Involving this Sympton

ENDS
PREPARATION OF G8D
PROCESS
g8d0 042606.vss
 Sympton has been BEGIN Global 8 Discipline
Defined and Meets G8D CREATION OF Process Proposed
Application Criteria G8D TEAM by FORD [D1]

Has Authority to
Identify Champion Make Changes &
of System or Process Able to Allocate
Resources

Responsible for
Managing the
Team, Directs
Identify Team Leader Decision Making,
and is Primary
Spokesperson

Responsible for
Providing Technical
Selects Team Members or Facilitative Input,
Based on Skills and Carrying Out
Knowledge Associated with Assignments,
the System or Process Offering Feedback,
and Clarifying
Issues

Establish
Team Objectives and
Membership Responsibilities

Develop Team Procedures

and Working Relationships

COMMON G8D TASKS

1. Document the Changes List Team Membership
2. Review Team Composition on the G8D Report
3. Review Measurables
4. Determine if Service Action is Required
5. Review Assessing Questions This does not Mean
6. Update the G8D Report ENDS that Membership is
CREATION OF G8D Stagnant through out
TEAM the G8D Process (See
g8d1 042606.vsd Common Task #2.)
 BEGIN Global 8 Discipline
G8D Team has
been Established Process Proposed
DEFINING THE PROBLEM by FORD [D2]

Review Available Data

D4b
to
D2

Apply G8D Yes Can

Application Criteria Symptom be
for Each Sympton Subdivided
?

No
D2A
to State Sympton as an
D0 Object and a Defect

Yes
Is Cause Known?

No

Document Problem
Statement

Develop Problem
Description (IS / IS NOT)

Identify & Analyze

Process Flow

Identify Additional
Data Required
COMMON G8D TASKS
1. Document the Changes
2. Review Team Composition Collect & Analyze
3. Review Measurables Additional Data
4. Determine if Service Action is Required
5. Review Assessing Questions
6. Update the G8D Report
Does Does
Problem Reflect No Problem Reflect
"Something Changed" "Never Been There"
Situation? Situation?

Yes Yes

Use Yes Supplement Yes

Improvement Techniques G8D Process with Use G8D Process?
(e.g., DOE, Re-engineering, etc.) Improvement
Techniques?

No No
Review Problem Use
Description with Customer Improvement Techniques
and Affected Parties via (e.g., DOE, Re-engineering, etc.)
Updated G8D Report

SUSPEND G8D
ENDS PROCESS
g8d2 042605.vsd DEFINING THE PROBLEM
 BEGIN
DEVELOPMENT OF INTERIM Global 8 Discipline
Problem Description Process Proposed
has been Established CORRECTIVE ACTION (ICA) by FORD [D3]
PROCESS

Evaluate Need to Isolate

Effects of the Problem from
Customers may be
the Customer UNTIL Internal or External
Permanent Corrective
Actions are Implemented

Can the Customer Yes

Go To D4
Accept the Defect(s)?

No
SUSPEND D3
Eliminate 100% of the Evaluate the D0 PROCESS
Problem from Reaching Emergency Response Action
the Customer for Improvement

Actions must not

Create other Identify and Choose the
Problems Best Containment Action
Downstream

No
ICA Verified?

Yes

Champion Develop Action Plan,

Authorizes ICA Implement & Validate
Implementation ICA

No
ICA Validated?

Yes

Document the Actions and

Communicate Deployment
to Affected Functions
COMMON G8D TASKS
1. Document the Changes
2. Review Team Composition
3. Review Measurables Monitor ICA for Continued
4. Determine if Service Action is Required 100% Effectiveness
5. Review Assessing Questions
6. Update the G8D Report

ENDS
DEVELOPMENT OF ICA
g8d3 042606.vsd PROCESS
 Problem Description BEGIN
has been Established DEFINE & VERIFY Global 8 Discipline
and Interim Corrective Process Proposed
Action Implemented ROOT CAUSE AND ESCAPE by FORD [D4a]
As Required POINT PROCESS

Review & Update

the Problem Description
As Required

Study the Process; Possible Tools:

Process Flowcharting;
the Inputs, Outputs, & Cause & Effect Diagram;
Possible Causes Failure Modes Effect Analysis

Evaluate & Verify

each Cause on the
Possible Cause List

Can the Cannot be

No Considered as
Cause Make the
No Problem Come a Potential
and Go? Root Cause

Yes

Finalize Potential
Root Cause List

Is there Evaluate the Effects

Yes of each Potential
more than One
Potential Root Root Cause &
Cause? Their Interactions

No

Does the D4a

Root Cause Account to
for All Known D4b
Data?
Yes

Acknowledge the Verified

Root Cause & Document
on the G8D Report
COMMON G8D TASKS
1. Document the Changes
2. Review Team Composition
3. Review Measurables
4. Determine if Service Action is Required
D4b 5. Review Assessing Questions
g8d4a 042606.vsd 6. Update the G8D Report
Root Cause Analysis D4b Global 8 Discipline
Resulted in Multple Process Proposed
Potential Causes by FORD [D4b]

D4a
to D4b
D4b Assign Percent to
Contribution for each D2
Potential Root Cause
Yes

Do
the Potential Do
Root Causes Yes Seperate G8D's
Approximate 100% need to be Generated
Contribution to the for Each Root
Problem? Cause?

No No

Evaluate with the Team

Champion the Use of
Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

No Use
Use G8D Process? Improvement Techniques
(e.g., DOE, Re-engineering, etc.)

SUSPEND G8D
Yes
PROCESS

Supplement Yes Use

G8D Process with Improvement Techniques
Improvement (e.g., DOE, Re-engineering, etc.)
Techniques?

No

Acknowledge the Verified

Potential Root Cause(s)
& Document on the
G8D Report

COMMON G8D TASKS

1. Document the Changes
2. Review Team Composition
3. Review Measurables
4. Determine if Service Action is Required
g8d4b 042606.vsd D4c 5. Review Assessing Questions
6. Update the G8D Report
 Root Cause or Global 8 Discipline
Potential Root Cause(s) D4c
has/have been Defined Process Proposed
and Verified by FORD [D4c]

Review Process Flow &

Identify Control Points for
the Root Cause or Each
Potential Root Cause

Is the No
Current Control System
Capable of Detecting
the Problem?

Yes

Identify the Control Point

Closest to the Root Cause,
or Potential Root Cause(s),
AND Verify Effectiveness
in Detecting the Problem

Acknowledge the
Is the No Control System as
Control Point Capable Not Capable
of detecting the AND Needs
Problem? Corrective Action

Yes
D4c
to
Acknowledge the Control D5
Point as Verified Escape
Point & Document on the
G8D Report

COMMON G8D TASKS

1. Document the Changes
2. Review Team Composition
ENDS PROCESS 3. Review Measurables
OF DEFINEING & VERIFYING
4. Determine if Service Action is Required
THE ROOT CAUSE(S) AND 5. Review Assessing Questions
g8d4c 042606.vsd ESCAPE POINT 6. Update the G8D Report
 Permanent Corrective Actions BEGIN Global 8 Discipline
for the Root Cause(s) and Process Proposed
Escape Point have been CHOOSING & VERIFYING PCAS
Defined PROCESS by FORD [D5]

Options may be
Choose Option Performed in
in Performing a Series even
Decision Analysis though Depicted
as Parallel
D4c
to
Root Cause(s) Initiate Decision Escape Point D5
Analysis

D5A

Establish
Decision Criteria for Establish
Root Cause(s) PCA Decision Criteria for
Escape Point PCA

Review Any Data Ensure that the

ICA is Capable for
Involving Interim Duration of PCA Identify Possible
Corrective Actions Implementation Actions, Including
ANY Interim
Corrective Actions

Identify
Possible Actions for
Root Cause(s) PCA Choose the "Best"
Permanent
Corrective Action
Choose the "Best"
Permanent
Corrective Action
Verify / "Test"
Effectiveness
of Escape Point
Verify / "Test" PCA
Effectiveness
of Root Cause(s)
PCA

No
Escape Point
PCA Effective?
No
Root Cause(s)
PCA Effective?
Yes
Yes

Does
Yes Root Cause(s)
D5A PCA Affect No No
Verified Escape
Point?

Has
No Champion
Authorized the
Selected
PCA?
COMMON G8D TASKS
1. Document the Changes Yes
2. Review Team Composition
3. Review Measurables Update G8D Report
4. Determine if Service Action is Required
5. Review Assessing Questions
6. Update the G8D Report
ENDS
CHOOSING & VERIFYING
PCAS PROCESS
g8d5 042606.vsd
 Permanent Corrective Actions BEGIN Global 8 Discipline
for the Root Cause(s) and Process Proposed
Escape Point have been IMPLEMENT & VALIDATE
PCAS PROCESS by FORD [D6]
Defined

Options may be
Choose Option in Performed in
Implementing Permanent Series even
Corrective Action though Depicted
as Parallel

Root Cause(s) Implement Permanent Escape Point

Corrective Action

Develop Action Plan Develop Action Plan

for Implementing for Implementing
Root Cause(s) PCA Escape Point PCA

Implement Implement
Root Cause(s) PCA Escape Point PCA
per Plan per Plan

Replace ICA with

Root Cause(s) PCA Replace ANY ICA
AND Evaluate with Escape Point
Effectiveness for PCA AND Evaluate
Escape Point Effectiveness at the
Escape Point

Does Perform Validation of

Yes Root Cause(s) the Escape Point
D5A PCA Affect Yes PCA
Verified Escape
Point?

No

Perform Validation of No No
the Root Cause(s)
PCA

Permanent Corrective
Action(s) Validated?

Yes
COMMON G8D TASKS
1. Document the Changes
Confirm with Customer
2. Review Team Composition
that the Symptom has
3. Review Measurables
been Eliminated AND
4. Determine if Service Action is Required
Update G8D Report
5. Review Assessing Questions
6. Update the G8D Report

ENDS
IMPLEMENT & VALIDATE
g8d6 042606.vsd PCAS PROCESS
Permanent Corrective Actions BEGIN Global 8 Discipline
for the Root Cause(s) and ESTABLISHING ACTIONS TO Process Proposed
Escape Point have been by FORD [D7]
Implement & Validated PREVENT RECURRENCE

Review History
of the Problem
COMMON G8D TASKS
1. Document the Changes
Analyze how this 2. Review Team Composition
Problem Occurred and 3. Review Measurables
Escaped Detection 4. Determine if Service Action is Required
5. Review Assessing Questions
6. Update the G8D Report

Identify Affected Parties &

Opportunities for Similar
Problems to Occur and
Escape Detection

D7A

Identify the System's

Policies, Practices, and
Procedures that Allowed
this Problem to Occur Develop
and Escape to Plan to Implement
the Customer Systemic Actions to
Prevent Recurrence

Analyze How the

Conditions Above Could
Cause Problems Similar
to this One Champion Forward
No
Authorizes Actions Recommended
to Prevent Actions to Affected
Recurrence? Management?
Are there
No Possible Prevent
Go to D8 Yes Yes
Actions that Could
Cause Similar
Problems? Implement
Systemic Actions to Go to D8
Prevent Recurrence
Yes
SUSPEND D7
PROCESS Identify AND Choose SUSPEND D7
Actions to Prevent Validate the PROCESS
Recurrence Systemic Actions to
Prevent Recurrence

Verify Actions to
Prevent Recurrence
No Systemic Actions
to Prevent Recurrence
Are Valid?
No
Are the Actions to
Prevent Recurrence Yes
Effective?
Update G8D Report
Yes

ENDS PROCESS OF
D7A
ESTABLISHING ACTIONS TO
g8d7 042606.vsd
PREVENT RECURRENCE
 All Countermeasures BEGIN PROCESS Global 8 Discipline
for Problem have OF RECOGNIZING Process Proposed
been Implemented CONTRIBUTIONS by FORD [D8]

Select Key Documents and

Provide for their Retention

Reflect on the Teams

Successes & Failures

Document Lessons Learned

Recognize the Collective

Efforts of the Entire Team
in Solving the Problem

Mutually Recognize the

Particular Contributions
from each Individual

Celebrate Completion
of Problem Solving
COMMON G8D TASKS
1. Document the Changes
2. Review Team Composition
Update the G8D Report
3. Review Measurables
4. Determine if Service Action is Required
5. Review Assessing Questions
6. Update the G8D Report ENDS PROCESS
OF RECOGNIZING
CONTRIBUTIONS
g8d8 042606.vsd