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Production Management
Gestão da Produção
2012/2013
Course included in
Master (MSc) in Mechanical Engineering
Mestrado Integrado em Engenharia Mecânica
4. Methods Engineering and Process Design
A3 Report
Production ManagementGestão da Produção
Methods Engineering – A3 Report
What is the A3 Problem Solving or Report ?
• Is a Process that applies lean thinking to problem solving.
– It presents a report in a simple and structured way.
– It is a waste-free way for report writing and communication.
– It’s basic blocks provide a nice little template for lean thinking.
• Jamie Flinchbaugh 2012
– “By standardizing and making visible the process of identifying problems and
formulating solutions, individuals and companies can execute to their ideal
state.”
– A3 is the international standard name for the paper size 297x420 cm.
– The concept borne at Toyota to describe the process of getting report-
writing down to one page.
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
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Draft example from
Jamie Flinchbaugh
(2012)
Production ManagementGestão da Produção
Methods Engineering – A3 Report
When to use A3 ?
• Do use A3 when: – Collaboration in thinking is required
– There is the need to make thinking more visible among the teammembers (or your and someone else’s thinking)
– There is a gap of knowledge or obvious solutions
• Do not use A3 when: – There is an obvious solution to implement (you know it..)
– There is a theoretical solution jus needing to be tested
– It is used to fit the ongoing work into a report for credit
• A3 is not: – A research project
– A magic formula that fits all the problems. There is no standard.
– A debate about the form of the reports. Is a Process not a Form.
– A linear way. Pencil and eraser should be used along the process.
– It is not an individual process. It is to engage people.4
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
Standardizing and Simplifying
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Information Flow
The Four Quadrants of A3 Problem SolvingJamie Flinchbaugh (2012)
Production ManagementGestão da Produção
Methods Engineering – A3 Report
Types of A3 Reports
• Proposals, Strategic, Business Planning
– Environmental Scan
– SWOT Analysis
– Vision, Mission, Values
– Competitor Analysis
– Radar Chart and Gap Analysis
– Tree Diagram
– X-box (X-matrix)
– Deployment Plan
– Plan Review Status
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
Types of A3 Reports
• Process
– Problem
Solving
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Debashis Sarkar
2010
Production ManagementGestão da Produção
Methods Engineering – A3 Report
Basic Steps (not a standard):
• PLAN
1. Identify the problem or need
2. Understand the current situation/state
3. Develop the goal statement – develop the target state
4. Perform root cause analysis
5. Brainstorm/determine countermeasures
• DO
6. Create a countermeasures implementation plan
• CHECK
7. Check results – confirm the effect
• ACT
8. Update standard work
10The DEMING Cycle
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
Examples
11(Larry Rubrich in reliableplant.com)
Production ManagementGestão da Produção
Methods Engineering – A3 Report
Examples
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
Examples
13http://www.systems2win.com/
Production ManagementGestão da Produção
Methods Engineering – A3 Report
Examples
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http://www.coe.montana.edu
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Methods Engineering – A3 Report
Examples
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http://www.a3thinking.com
Production ManagementGestão da Produção
Methods Engineering – A3 Report
A3 Format for the Group Project (adaptable)
• Content
– THEME:
• Concise statement of what this A3 report is about.
– BACKGROUND:
• Note any contextual or background information necessary to fully
understand the issue.• Indicate how this problem affects the company’s goals or is related to its
values.
– CURRENT CONDITION:
• Insert a diagram that illustrates how the current process works.
• Label the diagram so that anyone knowledgeable about the process can
understand.
• Note the major problems (we like to put them in storm bursts to set them
apart)
• Include quantified measures of the extent of the problem – graphical
representations are best!16
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
A3 Format for the Group Project
• Content
– ROOT CAUSE ANALYSIS
• List the main problem(s)
• Ask appropriate “why?” questions until you reach the root cause. A rule-
of-thumb: you haven’t reached the root cause until you’ve asked “why?” at
least 5 times!
• List the answers to each why question
• Use simple analysis tools to identify causes
– TARGET CONDITION:
• Define the specific target(s)• Identify how the success will be measured
• State in measurable or identifiable terms
• Be concise and explicit
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
A3 Format for the Group Project
• Content
– PROPOSED COUNTERMEASURE(S)
• Insert a diagram that illustrates how the proposed process will work, with
labels.
• List the countermeasure(s) that will address the root cause(s) identified.
• Predict the expected improvement in the measure of interest (specifically
and quantitatively)
– IMPLEMENTATION PLAN
• List the actions which must be done in order to realize the Target
Condition, along with the individual responsible for the action and a duedate.
• Add other items, such as cost, that are relevant to the implementation.
– FOLLOW-UP
• (A3 process must be followed by the company, not by the group)
• Give some hints to support the follow-up process
• Remaining issues that can be anticipated.
• Ensure ongoing P-D-C-A 18
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Production ManagementGestão da Produção
Methods Engineering – A3 Report
Links
• http://www.leanlearningcenter.com/
• http://www.reliableplant.com/
• http://proferoinc.com/
• http://www.lean.org/
• http://www.systems2win.com/
• http://www.a3thinking.com/
• http://www.coe.montana.edu/ie/faculty/sobek/a3/index.htm
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