Solving Problems That Stick

Maggie Ellis

Alright, picture this. It’s the 1980s, big hair, neon everything, and Ford—yes, the car company—is revolutionizing the way we solve problems. They come up with the Eight Disciplines of Problem Solving—8D for short—and it didn't just stay in the car world. It’s like they handed manufacturing the blueprint for sanity.

d2388e72

Wait, wait—so 8D is like…manufacturing’s mixtape from Ford? Just on repeat in every factory now?

Maggie Ellis

Exactly! Busting those recurring problems. It’s not just fixing issues—it’s crushing them so hard they don’t even try to come back. At its core, it’s about structure. Clear, step-by-step. You kick it off with what we call D0 and D1—planning and pulling together a dream team. But here’s the magic unlock: documentation.

d2388e72

Oh yeah, 5W2H, right? The who, what, when…uh, and how many times have I seen that handwave when someone forgot their data? You’ve gotta make it stick, though.

Maggie Ellis

Yes, 5W2H is like your checklist on steroids. You start capturing everything—who saw it, what’s wrong, where it popped up, when it happened, and the numbers around it. You’re not just winging it. You’re setting the stage for success. And evidence? Oof, that deserves a spotlight all on its own.

d2388e72

Okay, let’s make it real for people, though. I mean, you’ve done this yourself, Maggie, yeah? Give us the story.

Maggie Ellis

Oh, totally. My first big 8D moment still haunts me. A production line hiccup—the worst. Components were failing at assembly and everyone pointed fingers. Classic chaos. But we jumped into digital 8D—used these forms to map out every tiny detail. By the time we hit Describe the Problem, I was like, “Wait, we know exactly where it’s breaking down.” Game-changer for how the team communicated and tackled it.

d2388e72

It sounds less like problem-solving and more like detective work. You’re building the evidence trail step by step.

Maggie Ellis

Yes! Detective work with zero magnifying glasses. And here's the thing—those early steps, the documentation and evidence, lay the stable foundation. Without it, your whole problem-solving process is like…a house of cards. Collapsing before you even get to why it failed.

d2388e72

Alright, so if I’ve learned anything, it’s this: document everything, bring your A-game evidence, and channel your inner problem-solving Beyoncé. That foundation’s gotta be flawless, right?

Maggie Ellis

Right! And once you get past this stage, it’s full speed ahead into containment. But, let’s not rush. This first step? It’s where you cement your win.

Maggie Ellis

Alright, we’ve nailed down our foundation—problem documented, evidence collected, the team aligned. Now it’s time to shift gears into containment. Think of it as the rapid-response phase of problem-solving. In manufacturing, when an issue strikes, acting quickly can make all the difference.

d2388e72

Fire drill? So, basically, you’re saying it’s grab-your-bucket-and-run time?

Maggie Ellis

Exactly. Imagine your entire production line is at risk because some defective parts slipped through. You’re shutting things down, quarantining products, and if you’ve got a supplier involved, it’s SCAR time—Supplier Corrective Action Requests. And trust me, that’s not a love letter.

d2388e72

Not a love letter, but definitely a “we need to talk” moment for suppliers. You’ve gotta get them on board, and fast, yeah?

Maggie Ellis

Oh, absolutely. You don’t just fix the problem on your side, you loop in every stakeholder. It’s like, hey supplier, grab a magnifying glass, pull out that data, and start solving this with us. Collaboration isn’t optional here; it’s your lifeline.

d2388e72

Yeah, that collaboration? It saved my neck once. One project I worked on—name redacted for drama’s sake—had a product issue that could’ve turned into a full-blown recall. We caught it early, though. Our team rallied, and the supplier? Total legends. They repainted 10,000 units overnight. Crisis averted.

Maggie Ellis

Whoa, wait. Overnight? That’s serious coordination. See, that’s the power of a good cross-functional team. When everyone drops their egos and just focuses on solving the problem, magic happens. And avoiding recalls? That’s the real win.

d2388e72

Totally. But it wasn’t just us dodging a money pit—it was also the brand’s reputation. Customers never even knew. And look, having systems in place so everyone knows their exact role? Game-changer. You’re basically turning chaos into teamwork on steroids.

Maggie Ellis

Absolutely. And whether it’s SCARs for a supplier or emergency inspections in-house, containment’s not just about quick fixes—it’s buying time for deeper analysis. The faster you slam the brakes, the better your shot at solving the root cause.

d2388e72

And just like that, you go from chaos to control. Honestly, containment’s kind of like survival mode—it protects everybody while you figure things out.

Maggie Ellis

Exactly. And speaking of figuring things out, let’s get into how modern tools make this whole 8D process feel, dare I say, smooth. Buckle up, Ruby, we’re diving into tech next.

Maggie Ellis

So, Ruby, let’s talk about those modern tools I mentioned. Here’s the thing: going from chaos to a smooth, effective 8D process isn’t magic—it’s all in tracking, collaborating in real-time, and making sure your fixes stick for the long haul. You can’t just wing it in today’s fast-moving environment.

d2388e72

I mean, sure, but tools are only as good as the people using 'em, right? Otherwise, they’re just glittery apps gathering dust.

Maggie Ellis

True, true. But there’s magic in the right setup. Let’s talk real-world here. Think EQMS—Enterprise Quality Management Systems. These beauties are like mission control for problem-solving. They link everything—FMEAs, root causes, even supplier corrective actions—into one integrated flow.

d2388e72

Okay, but EQMS sounds like it requires its own manual just to get started. Any tech-savvy shortcuts for, say, mortal humans?

Maggie Ellis

Fair point. For smaller teams or startups, something like Asana steps in beautifully. Create a project, and bam—you’ve got tasks laid out like D1 through D8. Add due dates, comment threads, and suddenly, everyone’s in sync. It’s structured but not over-engineered.

d2388e72

Oooh, I know where this is going—add a sprinkle of SafetyCulture, and you’re talking a full-mobile-friendly solution. Total lifesaver for on-the-fly problem-solving, where you toss in photos, record team input, and track things like a detective with a smartphone.

Maggie Ellis

Exactly! And let me share a little case study to show how this works in action. Picture this—it’s a manufacturing floor, thousands of units running weekly, and suddenly there’s a spike in defect rates. Everyone’s scrambling. The team grabs their digital tools—pulls an EQMS report to pinpoint patterns, uses Asana to track 30 action items, and logs photos in SafetyCulture during investigations.

d2388e72

And let me guess—they go from “Ah, panic!” to “Ah-mazing coordination,” right?

Maggie Ellis

Exactly! Within weeks, they traced the defect back to tool wear on a machine, revised maintenance protocols, and updated their FMEA in the same system. Here’s the kicker—the fixes weren’t just for that line. They used read-across assessments to apply the lessons company-wide.

d2388e72

See, that’s next-level thinking. It’s not just about fixing the moment—it’s about future-proofing. And really, Maggie, isn’t that what these 8D tools are all about? Turning lessons into lasting impact?

Maggie Ellis

Absolutely. Look, whether it’s EQMS, simple task apps like Asana, or the real-time brilliance of mobile tools, it’s about getting everyone on the same page and never losing sight of the long-term goal. The big win isn’t solving one problem; it’s building a culture where problems don’t stand a chance.

d2388e72

And on that note, I think we’ve cracked it. 8D, technology, teamwork—it’s the trifecta. Any parting thoughts, Mags?

Maggie Ellis

Yeah—disruption’s not a bad thing. It’s the first step to real innovation. So, take the leap, grab the tools, and fix what needs fixing. And remember—don’t just solve problems. Solve them so well they never return.

d2388e72

Poetic as always. Alright folks, that’s all for today! Thanks for tuning into Being Disruptive. Now go out there and, as Maggie always says…

Maggie Ellis

Own the chaos.