Global 8D Reference Guide

Global 8D
Reference Guide
The subject matter contained herein is covered by a copyright owned by Ford Motor Company, Dearborn, MI.
©Ford Motor Company, 2005
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Filename: g8d_ref_guide.doc 1 of 23 Date Issued: 12/22/2004

Originator: FDI Date Revised: 12/22/2004
Property of Ford Motor Company
Elements of There are three elements to G8D:
G8D • Problem Solving Process
• Reporting Format
• Corporate Standard
Change- A problem is a deviation from expectation, or any unwanted effect where the cause is not
Induced and known. The nature of this deviation takes two distinct forms giving rise to change-induced
Never-Been- and never-been-there problems:
There
Change-induced problems: Initially, the Never-been-there problems: The
Problems
system operates as expected, but at some performance of a system has never achieved
point it suddenly deviates from the expected the expected level.
performance level.
Problem A reliable product or process is one in which failure modes are avoided. The ultimate goal of
Correction problem resolution is to prevent problems from occurring. Even with the most disciplined
and Problem process some level of mistakes is inevitable, and mistakes lead to problems. Once a problem
Prevention has been detected, it must be corrected and resolved. To resolve a problem, counter-measures
must be taken to ensure that the problem and others like it do not recur.
Inductive and G8D uses both inductive and deductive approaches to resolve a problem.
Deductive An inductive approach starts from data based on observation and sets out to develop a theory
Approach consistent with the data. During the initial stages of applying the G8D process, the approach
is primarily inductive. Data is collected and analyzed to describe the problem being resolved.
Alternative root cause theories are identified and compared to the problem description. The
theory is selected that is most consistent with the data that describes the problem.
A deductive approach starts from a given theory and attempts to prove that a theory applies
in a particular situation by collecting and analyzing data and seeing if the data is consistent
with the theory. After identifying the root cause, deductive methods are used to confirm that
the selected root cause is the actual root cause. Finally, deductive methods are used to
permanently correct for the root cause and ensure that the problem, and others like it, does
not occur in the future.

G8D and There are two 6-Sigma processes used in Ford: DMAIC and DCOV. DMAIC is a systematic
6-Sigma methodology for reducing defects resulting from a process. DCOV is a disciplined
methodology for designing and manufacturing products that perform at, or above, the level
expected by the customer.
G8D, DMAIC, and DCOV form a complementary suite of problem resolution approaches,
with G8D best suited to resolving special cause or change-induced problems and DMAIC
best suited to common cause problems, which includes never-been-there problems. DCOV is
suited to prevent both special cause and common cause problems.
Other Other problem-solving methods that are sometimes used within Ford and outside of Ford
Problem include: 14D, High Mileage Resolution Process (HMRP), Shainin, and Structured Inventive
Solving Thinking (SIT).
Methods
G8D Tools Tools used to facilitate the G8D process include:
• Flowcharts — can be used throughout the G8D process to identify key actions inputs,
outputs, and decision points, and to check progress
• Assessing questions — help G8D teams determine if the steps of the Global 8D process
have been completed appropriately
• Problem-Solving Worksheet — ensures consistent application of the G8D process
G8D Web The Global 8D on the Web application is the single-source location for G8Ds within Ford and
Application its supply base. G8D teams should begin using the Web application at D0. The Web
application provides teams with a valuable tool to track and document the G8D process and
additional structure to the problem-solving process by asking for key information at each
step. It is also a communications tool for teams not located together geographically and a
“lessons learned” database of past problem-solving efforts within Ford Motor Company.
Section 2: Prepare for Global 8D and Establish the Team

D0
D0 Goal The goal of D0 is to prepare for the G8D process. Key tasks are to:
• Define and quantify symptom(s)
• Select an Emergency Response Action (ERA)
• Verify an ERA
• Develop an action plan and implement an ERA
• Validate an ERA
• Ensure G8D meets application criteria
• Determine if the symptom duplicates an existing G8D, or is a new G8D issue
• Initiate the G8D process

Symptoms The G8D problem-solving process distinguishes between problems and symptoms.
Symptoms are measurable events or effects (that must be experienced by customers) that
indicate the existence of one or more problems. Without a symptom, you don’t know that
there’s a problem.
The G8D process at D0 provides a means to respond to symptoms. Symptoms should only be
considered when they can be measured or quantified. If symptoms cannot be measured then
there probably is not enough information about the problem. Quantification may come from
data that already exists, such as warranty repairs/costs or customer satisfaction surveys.
Sometimes, measurable ways to quantify the symptom may have to be developed.
Emergency An ERA is any action taken to protect customers and affected parties from the symptom(s) of
Response the problem while it is determined if a G8D is necessary. An ERA is not always necessary.
Action The seriousness of the problem and its effect on the customer will determine if an ERA is
required. For example, problems that potentially affect safety will almost certainly require an
ERA.
Select, Verify, The most appropriate ERA is usually best identified by a small number of people, for
Implement example, the champion and one or two people with knowledge of the system that has the
and Validate problem. Once the best ERA is identified, the fact that it will protect the customer from the
an ERA symptoms of the problem must be verified before it is implemented. Verification is normally
based on an engineering test.
After implementation, an ERA must be validated to confirm that it is successful and does not
introduce additional problems. In the context of G8D, verification and validation have
distinct meanings.
• Verification provides evidence, before the ERA is implemented, that it will protect the
customer from the effects of the problem.
• Validation provides evidence, that, once implemented, the ERA is protecting the customer
from the effects of the problem.
Application Six criteria must be met before initiating the Global 8D process:
Criteria 1. The symptom has been defined and quantified.
2. The G8D customers experiencing the symptom and the affected parties have been
identified.
3. Measurements taken to quantify the symptom(s) demonstrate that a performance gap
exists, and/or the priority (severity, urgency, growth) of the symptom warrants initiation of
the G8D process.
4. The cause is unknown.
5. Management is committed to fixing the problem at the root cause level and preventing
recurrence.
6. The problem is too complex for one person working alone to resolve.
If all six criteria are met and no other G8D teams are working on the same or similar
problems, then the G8D process should be initiated.

D1
D1 Goal The goal of D1 is to establish the team. Key tasks are to:
• Identify the team’s champion
• Identify the team leader
• Determine whether team members have the process and/or product knowledge, allocated
time, authority, and skill in the required technical disciplines to solve the problem being
addressed and implement corrective actions
• Select team members
• Establish team goals and membership roles
Group It is important that those working on a G8D project work as a team and not as a group.
Versus Team • A group is a number of individuals with a common goal, but who may work independently
and without interaction and collaboration (e.g. a group of kayakers, each of whom is
paddling their kayak to achieve their individual goal of moving through the water).
• A team is a number of individuals working together as a cohesive unit toward a common
goal. Team members use both interdependent and collaborative efforts to reach the goal
(e.g. a team of rowers who are each operating the oars, acting as a cohesive unit to reach
the common goal of moving through the water).
Determine A team can be more successful by following certain guidelines for team membership:
Team • Limit membership to between four and seven members. Fewer than four members will not
Membership produce enough innovation. Teams with more than seven members may experience
interpersonal problems and may have trouble reaching agreement.
• Choose members with the right skills, knowledge, resources, authority, etc., to help solve
the problem.
• Choose the right mix of qualifications. Don’t choose everyone from the same department
or with the same job functions. People with different experiences and talents will help
teammates see the situation from different perspectives.
• Change team membership as needed throughout the project. At different times, various
expertise or information may be needed. Allow members to rotate on and off the team.
Team Roles Once a G8D team has been selected, team members must work as effectively as possible. The
G8D process depends upon the efforts of all team members to achieve the team’s objectives.
To do this, each member performs one or more of the following roles:
• The champion has the authority to make (and implement) decisions regarding Interim
Containment, Permanent Corrective, and Prevent Actions. He or she also supports the
team’s problem-solving efforts throughout the process

• The team leader leads team members through the G8D process. This person has leadership
and interpersonal skills.
• The time manger ensures that the team makes the best use of meeting time.
• The scribe ensures that all important conclusions are clearly documented for all to see.
• The recorder generates, holds, and publishes team reports, such as G8D reports, meeting
minutes, action plans, etc.
• The facilitator’s primary task is to help with interpersonal issues such as resolving conflict,
arriving at consensus (when required), handling negative group behaviors, etc.
• Team members are selected to participate on the G8D team because of their experience
and knowledge. They are subject matter experts who may not perform another role on the
team. Team members might change during the G8D process.
Some guidelines to keep in mind when implementing team roles are:
• Roles are not people; roles are functions that people fulfill. However, certain people are
better at certain roles than others. For example, someone who is not assertive may make a
poor time manager or leader. The team should match individual skills to roles so that each
role will be handled as effectively as possible.
• Members often hold roles for the duration of the meeting or longer. Roles can be changed
in the middle of a meeting. However, when team members exchange roles in the middle of
a meeting, confusion can result unless all team members are aware of the change.
• When the leader or facilitator offers an opinion, they automatically leave their role to
become a team member. The team will be without a leader or facilitator until someone else
assumes the vacant role.
• Some roles can be shared. For example, facilitator and time manager, or recorder and
scribe. Team leader and facilitator roles should not be shared.
• Facilitation is essential throughout discussion. This means that the person who is
facilitating is not participating directly in the problem-solving task. When all team
members have acquired the skill of facilitation, the person who potentially has the least
amount of input during any given meeting should adopt the facilitator role.
Section 3: Describe the Problem and Find Root Cause

D2
D2 Goal The goal of D2 is to describe the problem. Key tasks are to:
• Develop a problem statement by identifying “what is wrong with what?” in quantifiable
terms.
• Describe the problem in detail in terms of what it “is” and “is not” (i.e., develop an
objective problem description).
• Identify the process flow
• Identify, collect, and analyze additional data
• Ensure the problem relates to a something changed situation
• Review the problem description with affected parties
In D2 teams develop a clear problem statement and an objective problem description to help
them focus their effort on the real problem and avoid jumping to conclusions or making
unsubstantiated assumptions about the problem. A problem statement is a simple, concise
statement that identifies the object and the defect of a problem for which the cause is

unknown. The purpose of the problem statement is to narrow the search for the root cause and
serve as a starting point for the problem description.
Preliminary When developing a problem statement, the team first establishes a preliminary problem
Problem statement in terms of the object and defect of a problem. The object and defect are identified
Statement by asking the question “What is wrong with what?”
• “What is wrong” is the defect, which is an unwanted characteristic present in a product or
process.
• “...with what?” is the object, which is the name given to a specific product or process that
exhibits the defect
The Repeated Once a team has a preliminary problem statement it is refined by asking the question “Why is
Whys that happening to that object?” Refining the preliminary problem statement helps to focus
Technique efforts on a single problem with a single root cause, get as near as possible to the root cause
using existing data, and 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 called
the repeated whys technique or stairstepping. The team continues asking the question until
the question cannot be answered with certainty (i.e., until the answer is, “I don’t know.”). The
last object and defect with an unknown cause is the problem statement.
Observations When developing the problem statement the team should make observations and not draw
versus conclusions about the problem. The differences between observations and conclusions are
Conclusions summarized below.
Observations
• Consist of observable, quantifiable information
• Have a high incidence of accuracy
• Tend not to be disputed since they are usually just a list of facts
• Usually describe what, who, when, where, and how big
• Detail the effects
• Should be done before drawing conclusions
• Are frequently done incompletely
• Tend to be considered less important, go unrewarded, and are unappreciated
• Are made in D2
• Reveal the symptom/defect
Conclusions

• Are decisions based upon deductions
• Have a low incidence of accuracy
• Tend to be debated until proven valid by testing
• Usually describe the “why”
• Describe the cause
• Should be done after making observations
• Are frequently jumped to
• Are highly valued, usually rewarded, and reinforced
• Are drawn in D4
• Focus on cause
The key to accurately defining and describing a problem is to make observations and save
any conclusions for after all information is gathered and examined. Once a conclusion is
reached, it is difficult for most people to re-examine the facts.
Collect Additional data will probably be required to refine the preliminary problem statement and
Additional develop the problem description.
Data To ensure that relevant data is collected, information surrounding the problem should be
examined closely. The team should develop a common understanding of the process
associated with the problem by identifying the process flow and documenting this on a
flowchart or process map.
Once there is a common understanding of the process, the team can focus on the process steps
relevant to the problem and gather information.
Problem The problem description is the output of a process used to amplify the problem statement in
Description terms of what, where, when, and how big. This is often called the “Is/Is Not”. The problem
description defines the boundaries of the problem, in terms of what it is and what is not but
logically could be. This helps to narrow the search for the root cause of a problem by limiting
or excluding illogical possibilities and provides the basis for testing the cause of the problem.
Teams should use page 1 of the Problem-Solving Worksheet when developing a problem
description. The problem description is developed by asking:
• What the problem is and what it is not, but logically could be
• Where the problem is and where it is not, but logically could be
• When the problem occurs and when it does not occur, but logically could
• How big the problem is and how big it is not, but logically could be
It is important to take the problem statement and develop a problem description, because
everything teams do at D4 in identifying the root cause of the problem builds on the problem
description developed during D2. How well teams identify the root cause at D4 depends on
the information they summarized in D2.
Review Nature As discussed in Section 1, G8D is best suited to resolving change-induced problems, while
of the Problem other methods are better suited to resolve other types of problems. At the end of D2, an
objective and detailed problem description has been developed, and the Is/Is Not information
should now be reviewed to verify the problem is a change-induced problem. For example:
• When a problem is seen after a particular date, but not before, this indicates a change-
induced problem
• When a product had a problem since first being produced, this indicates the problem is not
change-induced, and a problem solving technique such as DMAIC 6-Sigma would be

more appropriate
If the problem is a change-induced problem, it is time to move on to D3. However, before
beginning, the problem description should be reviewed with those affected by the problem to
ensure it is a good problem description.
Further refinements to the problem description might be needed after this type of review.
D3
D3 Goal The goal of D3 is to develop an Interim Containment Action (ICA). Key tasks are to:
• Re-evaluate the ERA with knowledge gained in D2
• Identify alternative ICAs
• Compare alternative ICAs to selection criteria
• Select the best ICA
• Verify the ICA
• Implement the ICA
• Validate the ICA
Interim An ICA is any action that prevents customers from experiencing the symptoms of a problem.
Containment An ICA isolates the effects of the problem from both internal and external customers until a
Action (ICA) Permanent Corrective Action (PCA) can be implemented. An ICA is similar to an ERA;
however, ICAs are more refined and focused than ERAs. Like ERAs, ICAs:
• Attack the symptom of the problem
• Are verified for effectiveness before they are implemented
• Are monitored while they are in use
• Are documented
• Add cost to the process/operations
An ICA works against the problem symptoms, not against the root cause.
Re-evaluate When developing the problem description in D2, more knowledge is gained about the
the ERA problem than was available in D0 when an ERA may have been implemented. Assuming
that the customer still needs protection from the problem, the team should re-evaluate the
ERA since this may be effective and cost-efficient enough to continue as the ICA. Often,
however, the team’s greater understanding of the problem allows them to replace the ERA
with a more effective and less costly ICA.
Develop and Six tasks are required to develop and implement an ICA:
Implement an • Identify alternative ICAs
ICA
• Compare alternative ICAs to selection criteria
• Select the best ICA
• Verify the ICA
• Implement the ICA
• Validate the ICA
Identify Brainstorming helps to identify alternative ICAs. Teams can also consider how the ERA
Alternative might be modified to form an ICA. Although the team may have decided not to continue
ICAs with the ERA, armed with the knowledge of the problem that they gained in D2 the team
may be able to modify the ERA to make it more effective and less costly.

Compare To select the best ICA from a list of alternatives, the team first establishes selection criteria.
Alternative Typical selection criteria include, the time frame within which the ICA should be
ICAs and implemented, a minimum performance level, and a cost target. Selection criteria fall into two
Select the Best categories: features that must be present in an ICA (Givens) and features that would be nice
to have (Wants). As well as comparing each ICA option to the selection criteria, the team
must analyze the risks of implementing each option before selecting the one ICA with the
best balance of benefits and risks.
Verify an ICA Once selected, an ICA must be verified. As with an ERA, verification of an ICA provides a
comparison of the effect of the problem with and without the ICA. Verification also
confirms before the ICA is implemented that the customer will not experience the problem
and that no new problems will be introduced. Verification is normally based on an
engineering test. However, in some situations, ICA verification may simply be common
sense, for example, where the ICA is to stop shipment of the product with the problem, it is
clear that this will protect the customer from experiencing the effect of the problem.
ICA To achieve effective ICA implementation, it is useful to develop an action plan describing
Implemen- who needs to do what by when. The action plan should also include a clear statement of the
tation Action objective of the implementation. The action plan can also be used to demonstrate to the
Plan champion that all the necessary actions have been identified. An ICA should not be
implemented without the champion’s knowledge or involvement. The Deming/Shewhart
Plan, Do, Study, Act (PDSA) cycle can be used as a guide for implementing an ICA.
Software packages such as eTracker are also available to facilitate action plan development
and management.
Validate an After the ICA is implemented, it must be validated. Validation is ongoing evidence that the
ICA implemented action is doing what was intended without introducing any new problems.
Validation is based on data that reflects the effect of the problem on the customer (e.g., data
that quantifies the symptoms of a problem). Validation should always follow successful
verification, and provides evidence that the ICA is masking the problem symptoms
experienced by the customer.
D4
D4 Goal The overall goal of G8D is to resolve change-induced problems. D4 helps to achieve that goal
by determining and verifying the root cause and escape point of the problem. The output from
D4 sets the stage for eliminating the problem so that it never occurs again. The primary tool
used during D4 is the Problem-Solving Worksheet.
The process for completing D4 is divided into two paths:
• Determine the root cause
• Identify the escape point
Root Cause G8D teams determine the root cause of a problem in D4 by analyzing information using a
filtering process, which starts with a large number of root cause theories from which the
most-likely root cause theories that best explain the available data are selected. The root
cause is then identified as the most-likely root cause that fully explains the problem
description and can be verified by making the problem come and go.

Update the The first task in determining root cause involves updating the problem description that was
Problem developed in D2 so that it reflects the most current information about the problem. Accurate
Description information is imperative to the success of the G8D process. When updating the problem
description, the Is/Is Not analysis should be up-to-date and all entries in the Is/Is Not analysis
should be facts. In addition, all information about the problem that can be gathered should be
gathered and any new information about the problem should be reviewed.
Complete a Once the problem description is updated, the team performs a Comparative Analysis.
Comparative Change-induced problems stem from changes and typically, the root cause of the problem
Analysis will relate to one or more of these changes. The Comparative Analysis allows the team to
examine facts that surround the problem to identify differences and relevant changes.
Completing a Comparative Analysis results in information that has been filtered to remove
what is unlikely or unfounded. This ensures that the team will focus only on those root cause
theories relevant to the facts surrounding the problem.
There are two components to completing a G8D Comparative Analysis:
1. Examine Is/Is Not to identify differences, that is facts that are only true of the IS column
when compared to the IS NOT column. Differences may be related to methods,
equipment, measurements, people, or the environment.
2. Examine differences to identify changes; that is things that have changed in, on, around, or
about the differences. Changes should also be related to methods, equipment,
measurements, people, or the environment.
The Differences and Changes are documented on page 2 of the Problem-Solving Worksheet
Develop Root Following completion of the Comparative Analysis, teams develop root cause theories about
Cause how the problem could have occurred. Root cause theories are statements that explain how a
Theories change (or combination of changes) may have caused the problem or created the unwanted
effect. Teams develop root cause theories by asking the question, “How could this change
have caused the problem?” The root cause theories are documented on page 3 of the problem
solving worksheet.
Test Theories The team tests its root cause theories to determine the most-likely root cause theories by
to Identify the using a process of elimination to determine those theories that best explain the available data.
Most Likely Team members critically evaluate each theory against the Is/Is Not data to test the plausibility
Root Cause of each theory. For each Is/Is Not pair, the team asks, “Does this theory account for both the
Theory Is and the Is Not?” The results of testing the most-likely theories are documented using the
test matrix on page four of the Problem-Solving Worksheet. A coding system such as ‘+’, ‘-‘,
‘?’ as outlined below is used in completing the worksheet.

Code Meaning
+ The root cause theory completely explains an Is/Is Not pair
- The root cause theory does not completely explain an Is/Is Not pair
? It is unclear whether the root cause theory completely explains an Is/Is Not pair
Root cause testing allows the team to select the best or most-likely root cause theories on the
basis of facts alone. That is, root cause theory selection is not made by subjective judgment.
When it is feasible and practical to do so, the team should resolve items with question marks
(?s) by collecting additional data and re-testing the theory against the new Is/Is Not data.
Ideally, the worksheet should end up with very few or no question marks. However, it is not
always feasible or practical to collect sufficient data to eliminate all question marks. When
this happens, the team should identify any theory with a combination of pluses and question
marks as worthy of root cause consideration and eliminate any theory with one or more
minuses. In practice, sometimes more than one theory may pass testing with a combination of
pluses and question marks. When this happens, each passing theory will require further
investigation. If only one root cause theory passes testing (with all pluses or a combination of
pluses and questions marks), then this is the most-likely root cause theory.
Verify the Before a most-likely root cause theory can be selected as the root cause of a problem, it must
Root Cause be verified. Verification involves team members manipulating the most-likely root cause
variable to make the problem come and go, or switching the problem on and off.
The Escape Once the team has verified the root cause, it must determine how the problem escaped to the
Point customer. This is referred to as identifying the escape point. The escape point is the place in
the process closest to where the problem occurred and where the effect of the root cause
should have been detected and contained but was not. To identify the escape point, team
members need to ask and answer two questions — “Why did we not discover and contain the
problem when it occurred?” and “What caused the problem to escape to the customer?” To
answer these questions, the team must review the process in which the problem occurred.
This review focuses on the location in the process where the root cause occurred. Its goal is to
determine where the problem escaped to the customer.
Verify the The team must verify what it has identified as the escape point of the problem. This is best
Escape Point done by “turning the root cause on” and establishing whether the method used to detect the
problem (termed the control system) does so at the escape point. In verifying the escape
point, the control system should be restored to the state it was in when the problem occurred,
because an inadequate control system may be the cause of the escape point. The ICA must be
discontinued while the escape point is verified if this masks the problem symptoms.
• When the problem is not detected by the control system with the root cause turned on, it is
the true, verified escape point.
• When the problem is detected by the control system with the root cause turned on, it is not
the escape point.
If the problem is detected with the root cause turned on, either the identified escape point is
not valid or the control system has not been restored to the state it was in when the problem
occurred. If the control system has been restored to the state it was in when the problem
occurred and the problem is detected, the team needs to identify and verify an alternative
escape point. When the control system is not able to detect the effect of the problem at the
escape point, it is improved as a part of D6.

Section 4: Select and Implement a PCA
D5
D5 Goal The goal of D5 is to select the best Permanent Corrective Action (PCA) to remove the root
cause of the problem. D5 tasks focus on decision-making and verification, allowing the team
to select the best PCA based on benefits and risks and verify that the chosen PCA will work.
Adhering to the D5 process prevents the team from rushing into a solution and ensures that
the problem will not occur again and that new problems do not arise.
1. Chose and verify PCA for root cause.
2. Re-evaluate the escape point
Permanent Both ERAs and ICAs protect the customer from the effects or symptoms of a problem, but
Corrective they generally do not eliminate its root cause. Instead, these actions protect the customer from
Action (PCA) the symptoms of the problem while the underlying problem remains. A PCA, on the other
hand, is the best action that eliminates the root cause of a problem. The PCA removes the
problem’s symptoms by removing the problem itself. A PCA is the optimal solution to the
problem.
Choose and There are six key tasks for choosing and verifying a PCA for root cause:
Verify a PCA • Establish decision criteria
for the Root
Cause • Identify alternative PCAs
• Compare alternative PCAs to decision criteria
• Analyze risks
• Select best PCA
• Verify PCA
Establish The purpose of establishing decision criteria is to set the requirements that the PCA must
Decision meet including those necessary to eliminate the problem’s root cause and maintain or restore
Criteria customer satisfaction. These criteria frequently include cost and timing considerations and are
usually established in discussion with the champion. As with an ICA, the criteria used to
select the best PCA fall into the two categories of Givens and Wants.
Identify The team generates a list of alternative PCAs that would solve the problem at the root cause
Alternative by brainstorming. When alternative PCAs have been identified, the team evaluates how well
PCAs and each option meets the established decision criteria. This allows the team to assess how well
Compare several alternative PCAs meet defined criteria and identify the PCA that best meets the
Decision criteria through consensus based on discussion and learning instead of compromise.
Criteria
Analyze Risks After comparing PCA alternatives to the decision criteria, the team analyzes the risks
and Select associated with each option. Team members analyze the risks associated with alternative
Best PCA PCAs to ensure that the one best meeting the criteria will not create additional problems if
implemented. Using both decision criteria and conducting a risk assessment helps the team
make a sound, balanced selection, based on all available information. This ensures that the
PCA the team selects is the best choice for the situation.

Verify the Once selected, a PCA must be verified. Verification of the PCA proves, before
PCA implementation, that the PCA ensures that the root cause of the problem is eliminated and
will not introduce any new problems. Verification is normally based on an engineering test.
Re-evaluate After verifying the PCA, the team is ready to re-evaluate the problem’s escape point to
the Escape determine if the PCA affects its location. Normally the escape point that was identified in D4
Point and is not affected by the PCA. Sometime, however, the PCA does affect the location of the
Identify a New escape point. For example, a process operation might be eliminated as a part of the PCA. If
Escape Point, the escape point was located in this operation, a new escape point would need to be
If Necessary identified.
If, following the implementation of the PCA, the escape point identified in D4 is no longer
the escape point, it is likely because the PCA is such that the problem cannot recur in the
form that it did originally. A new escape point must be identified.
D6
D6 Goal The goal of D6 is to implement the PCA chosen in D5 to eliminate the root cause of the
problem, and to validate the PCA and monitor its long-term results. D6 tasks focus on
planning, problem prevention, and implementation. Thorough planning helps ensure that the
PCA implementation goes smoothly. Problem prevention involves examining each element
of the plan prior to implementation to ensure problems do not occur.
1. Implement and validate the PCA
2. Verify the control system
Implement and There are four key tasks for implementing and validating a PCA:
Validate a PCA • Develop an Action Plan for PCA Implementation
• Implement PCA
• Remove ICA
• Validate PCA
Develop an The action plan spells out the objective of the implementation, the standards and conditions
Action Plan that the implementation must meet, and the key steps that must be completed to achieve the
for PCA implementation. The key action plan steps are often documented in a simple table indicating
Implementation what the action is, who must complete it, and when it must be complete.
Once the action plan for the PCA implementation is complete, the team must analyze the
plan to determine what could go wrong and what might cause it to go wrong in each key
step. The team then identifies ways to prevent things from going wrong by developing
prevention actions and contingency actions to take if the prevention action fails.
Implement the After developing the action plan, it is carried out and the PCA is implemented. Once the
PCA and PCA is implemented, the team must remove the Interim Containment Action (ICA), as it
Remove the represents unnecessary cost and could make validation of the PCA difficult by masking the
ICA unwanted effect (problem symptoms).
Validate After implementation, the PCA must be validated. Validation confirms that the PCA
the PCA removes the problem at its root cause. It is ongoing evidence that the implemented action is
doing what was intended without introducing any new problems. Unlike the ERA and ICA,

which protect the customer from the symptoms of the problem, the PCA eliminates the root
cause of the problem. Nevertheless, since customers experience problems through their
symptoms, as with the ERA and ICA, validation of the PCA is based on data that reflects the
effect of the problem on the customer (e.g., data that quantifies the symptoms of a problem).
Evaluate the After PCA implementation, the team must ensure that, should the problem recur, it will be
Need to detected at the escape point. This means reviewing the way in which the problem is detected
Improve the at the escape point (i.e., the control system), and improving it if necessary.
Control System
Section 5: Complete the Global 8D

D7
D7 Goal The goal of D7 is to prevent recurrence. Key tasks include:
• Identify the underlying cause of the problem
• Prevent recurrence of the present problem
• Identify affected parties and opportunities for similar problems to occur and escape
• Analyze how similar problems could be addressed
• Identify, verify, implement, and validate actions to prevent the occurrence of similar
problems
• Identify the systemic cause of a problem and make recommendations for systemic
improvements
• Document technical lessons learned
Preventing Behind every problem that creates the need for a G8D team, there is at least one system,
Problem practice, procedure, or policy that allowed the problem to occur and escape. At D7, teams
Recurrence look at the big picture, and determine what allowed the problem to occur and escape.
Often, problems result from the carry-over of historic procedures, policies, and practices,
without carefully applying them to new situations. If these practices, procedures, or
policies remain unchanged, the same or similar problems will continue to occur.
D7 is the most important step in the G8D process. Identifying actions to prevent
recurrence of the present problem, and the occurrence of similar problems, and sharing
this information with other people in the company, allows them to take a proactive
approach and identify and resolve potential failures before problems occur. This leads to
improved quality and reduced cost.

Why Teams Do The following factors might explain why D7 is often not completed:
Not Complete D7 • D7 is never started. After the present problem is corrected, other priorities get more
attention.
• D7 evolves into a blame session. Rather than focus objectively on what happened, the
team focuses on who did/did not do something.
• The G8D process stopped at D3. Preventing recurrence of the root cause is impossible
because the root cause was never found.
• The G8D process was never used. One person created a G8D report.
• People fear consequences and believe identifying system inadequacies might get them
in trouble.
• The champion is too low in the company’s management structure to implement any
changes resulting from D7.
• No changes are implemented. System owners will not try to improve since they do not
have to live with the consequences, or the organization is unwilling to invest time or
resources into improvements.
Underlying Cause A problem has a visible and a less visible, or hidden part.
and Systemic Like an iceberg, a problem’s hidden part often is the largest part. A problem can be
Cause divided into three layers:
• Present problem — the problem directly associated with the problem symptoms due to
the root cause identified in D4
• Underlying problem — due to the underlying cause, which allows the root cause to
occur
• Systemic problem — due to the systemic cause, which allows the underlying cause to
occur
The underlying and systemic causes that form the hidden part of a problem have more
impact than the root cause and often take more time and effort to resolve than the root
cause. However, the benefits from resolving the underlying and systemic causes are
generally greater.

G8D resolves the present problem by identifying and eliminating the root cause through a
permanent corrective action (PCA). The underlying and systemic problems also can be
resolved by identifying the underlying and systemic causes and taking action.
Identify the The systems, methods, and procedures that allowed the problem to occur and escape form
Underlying the basis of the underlying cause of the present problem. By the time it gets to D7 the team
Cause(s) of the will have sufficient understanding of the problem to be able to identify the underlying
Problem cause by reviewing the problem history and analyzing how the problem occurred and
escaped. The simplest way to identify the underlying cause(s) is to use the repeated whys
technique (i.e., stairstepping) used earlier in D2 Describe the Problem.
During D2, the repeated whys technique focuses on identifying the problem statement and
starts by asking why the problem occurred, as described by the preliminary problem
statement. During D7, the repeated whys technique can be used to identify the underlying
cause by starting with the problem statement and asking why the root cause was able to
occur for every cause and effect identified until you get to the underlying cause of the
present problem.
Prevent the The answers generated from using the repeated whys technique to get to the underlying
Present Problem cause of a problem will point to the breakdown in systems, policies, and procedures that
from Recurring allowed the problem to occur and escape (i.e., allowed the root cause to occur). Each of
these breakdowns provides opportunities to improve the system and help prevent the
problem from recurring. By identifying the underlying cause, actions can be taken to
reduce or eliminate the opportunity for the root cause to recur.
Prevent Similar The underlying cause allows the present cause to occur and escape, and potentially allows
Problems from problems similar to the present problem to occur and escape. Once the team identifies the
Occurring underlying cause and takes actions to prevent recurrence of the present problem, it can
establish actions to address the potential occurrence of similar problems.
Just like the PCA that addresses root cause, any actions that prevent the occurrence of
similar problems by addressing the underlying cause should be verified before, and
validated after, being implemented. One significant difference between verifying and
validating the PCA and verifying and validating prevent actions that address the
underlying cause is that the customer does not experience a problem (i.e., the present
problem has been resolved and the similar problems are only potential problems). Thus
the verification and validation of the prevent actions for the underlying cause cannot be
based on determining that the customer no longer experiences the problem’s symptoms.


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Global 8D

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Section 2: Prepare for Global 8D and Establish the Team

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Section 3: Describe the Problem and Find Root Cause

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Section 5: Complete the Global 8D

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