Ford’s Global 8-D Root Cause Problem Solving Process

[db]

I’m not certain this is the right spot for this thread (Marc feel free to move it and delete this line – as if I have to say that, its your site! )

I came across something called Ford’s Global 8-D Problem Solving Process. From what I can tell, there are two main differences between this and the old 8-D. First, there appears to be formal checklists that accompany the steps. More importantly, a new step, Step 0 was added for you to consider whether your customer needs protection from the impact of the problem. (I wonder where that came from?)

Does anyone else have any better information?

[Sam]

db,
Also included with the checklist is a flowchart. There is also a list of questions that are available on the Ford web site.
The instructions note that the only person that can generate a G8D is a Ford person. "D0" refers to both a symptom and an emergency response action.
We received a G8D request last year. Section "D0" was completed by the Ford STA. I'm not sure if this would be so in all cases.

[db]

Sam, thanks for the input. If D0 is filled out by the STA, that would strenghen my belief that this step was a reaction to a significant problem Ford had a while back.....


Yes indeed...... very interesting!

[Spooked]

If the G8D evolves, just wait until you see the new BMW system! The PRR (Problem Resolution Report) has an expanded 8D, Fishbone analysis, 5why, IS/IS NOT and summary reports. All need to be completed for all problems. Takes about a week just to fill in the documentation! Nevermind the problem solving!

Given the simplicity of Toyota's system, why do other manufacturer's insist on loading these documents up so you less time to actually solve the problem?

[Geoff Cotton]

Spooked,

We ship parts to all other automotive companies except for Toyota.

How does the Toyota system differ to Ford's 8D?

[Spooked]

It was a previous company that I worked with that supplied Toyota (approx 2 years ago!), so it may well have changed.

But basically the standard paperwork consisted of a matrix to be completed of temporary(short term) and permanent containment and countermeasure sections, together with a validation area. This was supported by site visits to recognise the problem, together with containment and countermeasure implementation. Somewhat more progressive....

[Sam]

Toyota requires the folowing information for a response to a quality issue;
- Ref#,
- RTS#,
- Condition Title with part number and Accessory,
- Root Cause,
Interim/Permanent countermeasure,
Implementation date,
Contact information.

Response time:
- Key & Critical conditioon - 24 hour for short term fix, 5 days for long term fix,
- Minor - 15 days shotr term fix 30 days long term fix.

Suggested problem solving method:
- 5 Why, not requited to be submitted with response, unless requested.

The flow of this process is easy and straight forward. Allows one to concentrate on SOLVING the problem rather than an EXERCISE in problem solving.

[Spooked]

Sounds a lot like the Honda method in the UK. It works because the supplier/customer relationship is developed in a way that allows more process/product understanding of the supplier by the customer STA... Together with true understanding of the relevance and strengths of problem solving tools, rather than throwing them at the supplier and expecting them to get on with it......