Process Improvement Tool - 8D

Recently I came across this tool, which one of my client is using. It does not have that much of a publicity but a size-able number of organization actually follows it. Check it out.

8D is a problem-solving methodology for product and process improvement. It is structured into eight disciplines, emphasizing team synergy. The team as whole is better and smarter than the quality sum of the individuals. Each discipline is supported by a checklist of assessment questions, such as "what is wrong with what", "what, when, where, how much".

The Eight Disciplines

1. Use Team Approach
    Establish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group must select a team leader.

2. Describe the Problem
    Describe the problem in measurable terms. Specify the internal or external customer problem by describing it in specific terms.

3. Implement and Verify Short-Term Corrective Actions
    Define and implement those intermediate actions that will protect the customer from the problem until permanent corrective action is implemented. Verify with data the effectiveness of these actions.

4. Define and Verify Root Causes
    Identify all potential causes which could explain why the problem occurred. Test each potential cause against the problem description and data. Identify alternative corrective actions to eliminate root cause.

5. Verify Corrective Actions
    Confirm that the selected corrective actions will resolve the problem for the customer and will not cause undesirable side effects. Define other actions, if necessary, based on potential severity of problem.

6. Implement Permanent Corrective Actions
    Define and implement the permanent corrective actions needed. Choose on-going controls to insure the root cause is eliminated. Once in production, monitor the long-term effects and implement additional controls as necessary.

7. Prevent Recurrence
    Modify specifications, update training, review work flow, improve practices and procedures to prevent recurrence of this and all similar problems.

8. Congratulate Your Team
    Recognize the collective efforts of your team. Publicize your achievement. Share your knowledge and learning.

~~ Show me the data.

Thank you 2009, Welcome 2010

My believe is that every year we have to look back and see what progress we have made, do a minor tweak or adjustment and see where we are headed to next. In all reality, 2009 has not been an easy year, as do most years anyway. It will be a waste not to look back and take away learning points. The reality is that the world seems to have gone on a twisted economic cycle. Just to recap some of it the financial meltdown in US, the laying off of workforce all over the world, cutting back of spending from consumer to corporate, the almost always worsening weather and its getting really hot here, political disappointment (the usual picking and biting of each other but as a nation, no real progress), H1N1 another name for another strain of something as common as flu (but it has name because it kills us easily) and inflation on daily items.

So it does look crappy 2009, isn't it? well there was a feel scare but we all survived. And well, for all the stuff mentioned above, it is really beyond my control anyway. What I could do was what I can influence both from my personal action and personal thinking. In spite of all above, it was quite a fruitful year to complement a sad list above :) It is a year that I achieve my PMP, got an award in Software Testing for the organization I service, made a few friends, felt closer to God (yes, we pray more during the tough times), attended Wealth Mastery and preparation for fatherhood. Not that bad at all, I think.

So, come 2010, first of all is making real progress in planning and execution, as well as getting excited and fill my enthusiasm for life itself. I have to be more detailed now, and more precise in execution as this is one of the area I feel lacking the concentration. You know, we can be so distracted sometimes over things we have to do. I am really thinking of a year plan and then breaking them into quarterly plans so that the tracking is much better. From past experience, yearly plans are seldom looked at. Though with quarterly targets, I must live everyday by itself that is, everyday I must make progress and live it to the fullest, in passion, enthusiasm, love and joyfulness. We know we have today, but we do not know whether we really have tomorrow. And all of the daily activity jumbled up really packs it up and well hopefully still giving myself 7 or at least 6 hours of good sleep, plenty of water and pack in a couple of hours of good exercise and sun light every week.

A lot of cutbacks as well for 2010, I must reduce wastage time. Plenty of it, I suppose I should start with less TV, less games (yes, I still do games), less unhealthy food, less negativism, less pessimism and definitely less anger. I find that we live in a world full of pressure and pain. As yet technology has provided us with ample amount of convenience, I do find that with so much convenience, sometimes we do not appreciate life enough as it is. One thing I remembered that Keith Cunningham taught me, is that we have to set aside time to THINK. Have you really sit down and think today? Have we sit down and appreciate each and every present that God has give me and thank God and thank the people around me? Nope, have not done much of that. Come 2010, I definitely will.

One theme I want to make 2010 for me personally, is that 'To make this world a better place, with compelling future and exciting tomorrows for people around me, more so my family, so that the energy and enthusiasm around me will bring me to greater heights with God and understanding him better. To utilize my time so fully that I translate all my plans into outcomes that I wanted through perfect execution, as well as being generous with time for family and friends.

Yes Yes Yes, I can't wait for 2010!!

A Long Break

After about a couple of decade not writing blog, or at least that was how it felt like, I decide to write something today. But have no specified topic to write about, so lets just say I'll comment on something and everything that I can remember or know that is happening around me.

1. Economic Crisis OR Financial Crisis: Friends and family around me has been talking about the crisis and our stock market hitting rock bottom. That is then when we buy our house and invest a few 100k into blue chip stocks. Apparently over a period of 5 years, it will double your income. Well if that is true, lets us dig into our pocket and see how much we have :) 2nd problem, when do we exactly hit rock bottom :) And lastly, will you have that much to invest, just in case you have emergency. Well have to do a risk analysis already

2. Politics: Nothing like what I have read in the Sejarah textbooks. It is amazing how politic play a role today. It even seems to overshadow everything else like the police, the judiciary, the MACC and it is like all this pillars of the country is under political party. Well how sad that we can only make a decision every 4 to 5 years (that is, every general election). So, it is like we pay a movie ticket and watch it for 5 years. In between, you could do nothing about it. But one thing I do wish, can everyone involved in it just think of the country first, and everything else second. Look at the shape of the economy in our country. Companies are doing all the cost cutting for survival and we still can see a lot of 'advertisement' of political leaders, of that our country is in a good shape, of everything is good and fair. Nope I don't buy that. We have come into the working world and we only know one thing, only RESULT is justifiable. I don't see any activity that can justify result from 8/3/08 until now. So, zero result thus far, and not to mention the poor return of my EPF :( I thought the country did pretty well last year. Enough talk I suppose, I could go on forever.

3. Global Climate Change: I have said this many times, look at the kind of weather we have. It is really bad. It gets really hot and we have rain almost every evening. The climate is definitely changing, but how would it affect things globally. No one knows, hopefully our kids still gets to see what we see today.

4. PMP: I am doing this course and it is just so hard to answer some of the questions. I am really trying to work hard, after a long day of work, going back and do revision. It is not easy especially after a long day at work place. I suppose I need a lot of motivation and a lot of coffee. And hopefully with a lot of trial exam question and a lot of reading and memorizing, I can make it through.

5. Scandals: Is it me or what but there seems to be a lot of scandals lately. How come Dr Chua's issue re-surface? Scandal is subset of politics I suppose.

6. Meetings: I propose we held some meeting under the tree rather than air-con rooms. It is better for the environment and heck, important meeting of the state can also be held there, why not a small company's meeting, right.

7. Health: I seem to have problem with cough, it haunts me so often and it takes so long to get well :( Also it takes so long for me to recover after a game of basketball. My muscle ache is really a nuisance. Otherwise, pretty cool. Not to mention my mental stress increased when Man Utd went down to Liverpool at Old Trafford. But let me tell you what champion is made of, they will come back stronger AND so am I.

Well 7 points, represents 7 days in a week, 7 deadly sins, 7 heavenly virtue and of course the 7 dwarves :) I better get on with what I am doing and more updates down the road...

In the photo today: Indiana Choo and the Landmine Museum of Cambodia. Wow, boy do I look like .......

Blessed weekend ahead :)

Is Quality Relevant in 2009?

We first start to explore what happened to the Big Three automaker in USA. Ford, GM and Chrysler are the 3 top brands and are movers and shakers of the automobile industry in USA. We heard about them going to the Congress meeting and proposing a bail out plan to the Congress. You must be wondering what really happened to them, certainly their products do not lack in quality as compared to that of the Japanese giant like Toyota's.

In the past, according to ASQ Quality Progress Jan 2009 edition pg. 14, Toyota has a defect ratio of 1.5 defect per car compared to 3 defect per car for US automakers in the 1980s. Currently it is about level, i.e. Toyota has 0.9 defect per car compared to that of 0.95 of US automakers. So the quality is about the same which implies that quality did not cause the pitfall of US automaker. HOWEVER, the perception of quality did. Toyota cars are perceived to be high quality for the long commitment and continuous commitment to the capital Q. When we speak of Toyota, first thing that came to mind is quality, compact, fuel efficient and affordable. This bold well with consumer who has for a long time wanted to save on fuel consumption and have a good lasting car for usage.

Second area that we see defeat in US automaker is the COST. The CEO wages for US automaker is scandalous to start with and Japanese company like Toyota has a more hierarchical and controlled wage structure for them, even to the CEO, I believe. And in line with quality, Japanese company like Toyota also has a systematic quality, cost, improvement and effective mind set where continuous improvement is an everyday thing. What is inefficient is immediately taken care of. They do quality thinking everyday from top to bottom of the organization. At the end, since the quality right now is about the same, I believe the cost in producing a car of the same quality by both Toyota vs US automakers must be a huge gap causing the cost of non-quality being passed on to the user. Meaning if you buy from GM, Ford or Chrysler, chances are your car is more expensive than a Toyota not because it is better, but because you pay for 'a not so effective way of doing things'.

A summary from above, concentrate on Quality and Quality mind set across the organization, is the key to business survival in the long run.

And next question you may be asking, what about us Quality Professionals? Are we relevant or should we be the first on the chopping board because we are not exactly in the production line to produce goods for our customer? Or some management may brand it, it is time for survival fight, it is not time to think and spend more on Quality. Well, the time to invest and really push forward for us Quality Professionals is now.

In this economic environment, it is important that quality professionals demonstrate the ability and the promises of Quality as we have seen in articles, text books and concepts, adapt it into our environment and yield the benefits of it. Here are four ideas of how to start with:

1. Communicate the need of Quality across organization. Form action teams to get quality project executed with the buy in from management. Put yourself on the line, and get the buy-in from management to support such cause as to see the result that can be yield. As the environment is turbulent, go for short and effective projects that can yield a lot of savings for the organization or greatly enhance sales.

2. Communicate the need of Quality upwards. Speak to management using Cost of Quality (COQ) concept. Attempt to decipher and study the cost of failure and show how can quality projects and quality initiatives reduce that. Again put yourself in the line, and be pro-active to push through the understanding to management team.

3. Be pro-active and continuously look for ways to improve in terms of quality, processes, reduce wastage, improve output, reduce time and improve output even from each and every employees.

4. Record the results and outcomes of this projects as bolster for your future quality projects. This will be prove to you, your management and also to your organization that quality thinking and quality initiatives is important during good time, more so during the bad times. Sell Quality to your organization so that they embrace it.

So to answer the question, quality is relevant in 2009, and I can see that organization that is able to embrace quality by each and every employee shall emerge from this economic slump stronger, better and more competitive than ever before.

A Long Holiday (not enough though)

We had a pretty long holiday. A 2 day holiday for Hari Raya and then comes a working Friday and then off again for the weekend. It was a good break to relax and spend some time at home with family. After that it was the Christmas and New Year in the month of December and come January it is Chinese New Year. Well the flow of holiday seems good while the financial crisis and recession continue to hinder any mood of joyous and festivity. Coupled with the problem with Satyam, the overall outlook of the new year seems to be able to do much better. And of course not to forget our fellow human beings in Gaza, some of whom have died while Hamas and Israel continues to engage each other in a war that is punctuated by cease fire calls on and off, but they actually have been fighting all this while.

I like to spend a long holiday to really sit down and reflect on all this things. I may not be able to change anything at all, but, it is time for me, at least, to sit back and look at everything I understand from a perspective which I myself can accept. Whatever it is, things will get worst, according to the bible in the book of revelation. Probably that is a place to start to find peace in my heart amidst chaos in the world.

Haha.... that is all my ranting today :)

This is where I want to be.... ahhh....

Resolution 2009

From young, I have been setting targets and goals and it has been a few fruitful years. Though some of the years, the target was over-set, which causes me to few a bit down for not achieving it. There were also times, that it was fruitful and able to push me forward very well. I remember there were time that I didn't even know where I kept my resolution. Whatever it is, resolution is a tradition to me and I would go around asking people what their resolution is. Funny but interestingly, most people do not have one or a very vague one.

Here is how you can do it most effectively as far as I am concern. I am no expert but I must say that I have enough experience of it over the past 10 years to know what to do to setup your yearly resolution

1. FOLLOW what your heart tells you. Take time to meditate, think, think and think. Talk to yourself on what really makes you happy and what really propels you forward and make you feel good. Your heart must buy what your head says. Think with the very end in mind. I know this is tough, but when you set this year resolution, think as far as possible what would the end result be from your goals and actions this year. Begin with the end in mind, says Covey

2. THINK big, start small, walk persistently...

3. WRITE it down... anything you do, the one thing you MUST do is write it down. Somehow it helps your brain to stick the info in better.

4. Get an accountability partner to help ensure you follow up

5. Work on it, don't drift. Stick to the wall and look at it everyday. Ensure you move inch by inch towards it. At least millimeters.

There is a lot of good expert out there that have written great books about it, but if you are really serious about it, get excited and go for your goals that you have set out to do :)

In the pic: Still thinking of this vacation place. Forgot the name though.

2009

Strategic plan for 2009 and beyond

The year 2008 is coming to a close already and there have been many turmoil and turbulence along the way over the entire year. 2009 is not going to be better if we do not re-strategise now and change the business direction if necessary.

If the demand for the existing products and services are going to be lower the year ahead, something needs to be done now in order to mitigate the anticipated downturn.

Intel’s corporate strategy of building the US$33 Atom CPU to complement the matured US$100 Core-2 or Duo Core CPU, months ahead of the expected cyclic slowdown in demand for PC’s and electronics products, is able to sustain the growth in a trying economy. Now we can see a lot of ATOM based mini notebook or netbook from all sorts of brands.

Toyota’s corporate strategy of providing affordable mid-range saloon, Camry, is definitely creating a nice niche market. Its small car market is doing very well too. Its high end Lexus is also doing well competing with other up-market cars.

Core competence and NPI

I have the opportunity to share my knowledge and experience with some of the multi-national corporations (MNC’s) and local enterprises on supply chain management for global as well as local operations. The good news is that some of the MNC’s are still forecast a less than average growth for 2009 in spite of the imminent global recession in the horizon. Almost all of them ride on their core competence and outsource the rest, as well as having new product introduction (NPI) as a strategy to maintain or surpass the current organic growth

Dell’s corporate strategy to sell the production facilities in order to outsource production is a testimony of the adoption of the emerging virtual corporation, in order to focus on the brand power. Dell is very much in line with HP, Apple, Sony, and other computer manufacturers. Foxconn and Hon Hai are the major beneficiaries for the PC, notebook and mobile phone contract manufacturing in China and Taiwan having an annual sales of US$80 billion or so.

Toyota has perfected the Toyota Production System that is being adopted as the fundamentals for Lean Manufacturing. While the big three automakers in the USA are waiting for the US$25 billion government bailout, Toyota continues to be profitable with the subtle philosophy of simplification and standardization. Toyota has a very effective mass customization strategy that leverage with powerful customer and supplier relationships to deliver high quality cars at affordable prices.

Changing corporate and supply chain strategies for competitiveness and survival

Some of the movers and shakers of global supply chain management are redefining the conceptual framework, corporate and supply chain strategies, as well as operations management. All of them are customer focus and demand driven in order to provide perfect on time and complete delivery performance to ensure total customer satisfaction.

Foxconn has emerged as a global leader in contract manufacturing by supporting the clients’ supply chain strategies of low cost, high quality and delivery reliability. Its ODM (Original Design Manufacturer) strategy is years ahead of the competitors. It has aligned the corporate and supply chain strategies effectively.

IT-enabled Supply Chain Management

Many of the corporate IT projects have gone awry and failed to be effective because of the fundamental flaws of not addressing the business process and people first prior to IT implementation. This cart before the horse approach has been proven to be the root cause to implementation failure throughout the world.

Education and training can save the corporation millions of dollars that can go into consulting, implementation and customization without any real benefits and results.

Once the management and staff are properly educated and trained to develop and refine business processes and practices. The processes can then be clearly mapped with simplification in mind, making the configuration of an ERP/SCM system will be much easier and less time consuming and costs.

Human capital development

In a turbulent economy and marketplace, it is strategic to develop the human capital so that the best employees can be retained to ensure continuity during the recovery and upturn. It is also the best time to improve on the current processes, fine tune the effectiveness, and perfecting the on-time and complete (OTC) performance.

The way ahead

It is time for the enterprise to sharpen the supply chain thinking and invest in the human capital to become more innovative and competitive to cope with the turbulent economy and marketplace.

Source: Cicie Chin

The Last Lecture by Randy Pausch

I got a book, a small book for a run-down price during the MPH sales near my house. I think I have got more than what I have bargained for. For a few reasons, reason no. 1 is that it is small enough for me to finish reading within the appropriate time frame. I found that this days, I do not have the endurance to finish a book. It happened when I try to read the last thick book, that is, one of the Lord of the Ring book. Even when I tried to read the Harry Porter book, I couldn't finish one. So having bought and completed Randy's book is one of my personal achievement, that yes, I am still able to find the concentration to finish a book.

OK, moving forward, like to share with you what I have learned from the book, I figured that there will be a couple of people who is like me, who will always try to look for synopsis of the book rather than going through the whole book. The story begin frankly with our Professor Randy Pausch who has been diagnosed with cancer. The story goes on to tell us how he thinks life is all about, how he navigated it through and how he summarizes it for the benefit of his students and also his family in his last lecture in Carnegie Mellon University.

A few of the things that strikes out in the book or lesson learned are

1. Life meaning is about fulfilling your childhood dream (well, yes, that is what Randy has achieved)

2. He throws in a couple of adventure and the lessons that he had learned throughout life. I remember especially the one on head-fake.

3. It is also one of his happiness to be able to enable other people's dream, which is what a lecturer's life is all about. Training the students for the coming future in his field of expertise, that is the virtual reality.

4. His second last section is on how to life your life, that is, to Randy how he had live his life or his life lesson thus far. He is telling us his way that he thinks best of living it. No argument there with our professor.

5. His final remark is a bit touching. It is mainly for his wife and his kids, which he may not be able to see very much of in the time of his writing of this book. Nevertheless, he has given much thought and communication with his wife. The think about him is that he views communication, jovial and his choosing not to succumb in sadness or depression really sticks out strongly for him.

The book contains some photos which shows that the professor in his 40s still look very boyish and handsome and has been able to exude a strong sense of friendliness and influence in the place he works and people around him. The way his think and a piece of his thought throughout the book gives us a fresh insight of a dying man with a strong and firm battling spirit for the betterment of his family is really an inspiration to me. Not only that I am not facing such issues, but I am living my life so much less 'treasured' compared to him. Well if one thing Randy did in this book is to tell me to live my life to the fullest and in every moment of it. Live my life to the very minute of it, with the people that I treasure most.

Go get the book, the author is already dead now, that is, somewhere July/August 2008 this year. However he will always be remembered, at least by me. Go 'google' this famous name out or get a hand on his book. Have a nice day :)