In 2009, Dave Crysler was a brand new general manager who had just cleaned up the worst quality problem of his career. He got his boss on the phone, walked him through the investigation, the retraining, the new documentation, and the signed training records. His boss asked four words in response, and Dave didn't have an answer. In this solo episode, Dave breaks down what happened when they finally tested their fix, why it failed a week later, and why the verification step sitting inside every problem-solving framework is the one that always gets cut.
What You'll Discover:
• Why "how do you know?" is the hardest question anyone can ask about a fix you already closed
• The difference between confirming a process ran and confirming it produced the outcome you needed
• How a million-document order with duplicated serial numbers cost north of $60,000, and why the test that would have caught it cost under $1,000
• What happened when Dave deliberately recreated the error a week after all the retraining, and why the team thought he was tricking them
• Why any preventative measure that depends on somebody remembering isn't preventative
• Real examples of the same gap in completely different settings, from a company that never tested a backup restore to a certified quality system that closed a corrective action with "retrain the users"
• Why 8D, the Process Playbook, and P.E.R.R.R. all contain a verification step, and why it's the first thing cut every time
• The crawl, walk, run version of proactive testing, including the version that requires no technology at all
If your operation keeps solving the same problems, the issue probably isn't your root cause analysis. It's that nobody ever confirmed the fix worked. This episode gives you the question to ask, the math to justify the time, and a specific place to start on Monday.
