Global 8D - D7 & D8: Prevent Recurrence and Recognise Team and Individual Contributions

In this article I am going to cover the last two stages of the Global 8D problem solving process

I mentioned in my last article that some problem solvers’ activity will stop after having implemented and validated the permanent corrective action

These last two important steps ensure that: 

• This type of problem could never occur again
• Reinforce behaviours and esteem of the team and individuals

These last two steps in the G8D problem solving process are fairly short to explain and technically not much of a stretch. However, their importance should not be underestimated.

Astute problem solvers know that whenever a problem occurs there is normally a procedure, policy or practice (systemic) that has allowed it to happen. I call this the 'root cause of the root cause'. This needs to be established and resolved.

Just as important is recognition of the problem solving effort that has been afforded by the G8D Team and other individuals in the business.

Prevent Recurrence

As stated above, the next step is to examine the evidence established during the problem solving process and establish the policies, procedures and practices that led to this particular problem. For this we use a problem solving tool called 5 Why’s (sometimes called stair stepping).

In essence this involves asking the question “why” of the root cause until the root cause of the root cause is established. The question may be asked more or less than 5 times, it does not have to be 5!

Example: A small engineering company had problems with hole positions being out of tolerance in some instances. Having 'masked the problem' for some time with constant drill changes, the problem solving team discovered the root cause as being a worn spindle bearing. The 5Y’s exercise went something like this: 

• WHY – was the bearing worn?

• BECAUSE – it had become dry

• WHY – did the bearing become dry?

• BECAUSE – the operator did not carry out shift autonomous maintenance routines fully

• WHY – didn’t the operator follow maintenance routine fully?

• BECAUSE – he was not properly trained during induction

• WHY – was he not trained on induction?

• BECAUSE – his induction programme missed this off the sheet

• WHY – was this missing from the sheet?

• BECAUSE – the induction plan was not signed off by Engineering (Root Cause)

In fact, the induction process allowed for any manager to sign the induction plan (the systemic issue). The induction planning was changed to require function based sign off.

These systemic issues need to be fixed. The goal is to change the system that allowed the problem to occur in the first place and to prevent similar problems from happening.

Because these systemic issues are normally beyond the brief of the G8D team, these changes are made at management level. However the team does have the opportunity to offer recommendations for systemic improvements.

Recognise Team and Individual Contributions

This final step in the Global 8D process is about closing the process and involves: 

• Recognition and review of team experience (Cooperative Learning)

• Completing any unfinished business

• Closure process

Recognition and Review of Team Experience

The application of the process requires skills and experience of the business to be able to make progress towards a satisfactory problem resolution.

These skills and experiences are the reason the team are selected.

The problem solving process drives improved data-driven understanding of the problem at each step of the process. As more is understood about the problem, root cause and resolution, different skills and experiences will need to be 'drafted in' at various stages throughout the process.

Recognising the effort of the team and other individuals involved is important as it tends to reinforce behaviour and self-esteem.

Completing unfinished business

Making sure all the problem solving activities have been completed and include:

• Finalising and archiving documentation

• Recognising technical lessons learned

• Making final presentation to the Champion

• Expressing experiences from team member to team members (Cooperative Learning)

• Archiving all the lessons learnt from the problem solving effort

• Ensuring all other related documentation is revisited and up to date (e.g. FMEA’s, Control Plans, etc.)

Closure Process

In this final activity the team ensures that the completed 8D report is circulated to all concerned detailing all the above activities including the recommendations for systemic changes.

Next Time

There are a number of ways you can gain the skills necessary to apply this world class problem solving methodology in your workplace. Shortly I will share with you how you can gain access to training at various levels, quickly and easily that will get you on the path to solving problems effectively.

If your problem needs immediate attention, then you can contact me directly on graham.cripps@resultsresults.co.uk or you can visit our web site www.resultsresults.co.uk for more information.

Graham Cripps
Results Consortium Ltd