PDCA/A3PDCA/A3

Introduction to PDCAIntroduction to PDCA

PDCA was created by W Edwards Deming in the 1950’s as an easy to follow Problem Solving Cycle.

Deming was tasked with helping Japan rebuild its economy in the 1950’s.

His purpose was to use PDCA with a Continuous Improvement process to help rebuild Japanese industries so that they could compete in the world market in the future.

Where PDCA started.Where PDCA started.

Walter Shewhart Discussed the concept of the continuous improvement cycle (Plan Do Check Act) in his 1939 book, "Statistical Method From the Viewpoint of Quality Control“

W. Edwards Deming Modified and popularized the Shewart cycle (PDCA) to what is now referred to as the Deming Cycle (Plan, Do, Study, Act).

PLAN

DOCHECK

ACT

Custom erSatisfaction

INVEST IGAT E

CLARI FY O BJECT I VES

I DENT I FY PO SSI BLE CAUSES

BENCHM ARK BEST PRACT I CE

I DENT I FY T EAM RO LES

I M PLEM ENT Q UI CK FI X

EVALUAT E & VALIDAT E

P ILOT STUDY SOLUTIONTO V ERIFY DATA

COUNTERM E AS URE

TRAINING

COM M UNICATION

CO RRECT &ST ANDARDISE

REVI EW FEEDBACK &M AK E CORRECT I O NS

ST ANDARDI SE DO ,CHECK , ACT

ENLIGHT EN &IM PLEM ENT

CARRY OUT T RIALS T OPROVE CAUSES

ANALYSE DAT A T OUNDERST AND HOWPROBLEM OCCURS

IDENT IFY POSSIBLESOLUT IONS

I N VES T I GA T E

DET ERM I N E N EEDS

DI A GN O S T I C: REVI EW CU RREN T

PRA CT I CES .

BEN CH M A RKI N G: S U M M A RI S E A N D

CO M PA RE BES TPRA CT I CES .

EN LI GH T EN &I M PLEM EN T

DEFI N ERES PO N S I BI LI T I ES :

W H Y, W H A T & H O W

RECO GN I T I O N . RECO GN I S E T H E CO N T RI BU T I O N O F O T H ERS .

EVA LU A T E & VA LI DA T E

PILOT TRAININGPROGRAM

FEEDBACK

CO RRECT &S T A N DA RDI S E

REVI EW F EEDBA CK &M A KE CO RRECT I O N S

S T A N DA RDI S E DO ,CH ECK, A CT

Purpose:- To INVESTIGATE the current situation & understand fully the nature of the problem being solved.

I N VES T I GA T E

DET ERM I N E N EEDS

DI A GN O S T I C: REVI EW CU RREN T

PRA CT I CES .

BEN CH M A RKI N G: S U M M A RI S E A N D

CO M PA RE BES TPRA CT I CES .

EN LI GH T EN &I M PLEM EN T

DEFI N ERES PO N S I BI LI T I ES :

W H Y, W H A T & H O W

RECO GN I T I O N . RECO GN I S E T H E CO N T RI BU T I O N O F O T H ERS .

EVA LU A T E & VA LI DA T E

PILOT TRAININGPROGRAM

FEEDBACK

CO RRECT &S T A N DA RDI S E

REVI EW F EEDBA CK &M A KE CO RRECT I O N S

S T A N DA RDI S E DO ,CH ECK, A CT

Purpose:- To Enlighten the Team as to the Real Problem by analysing the Data and defining and implementing a solution plan.

I N VES T I GA T E

DET ERM I N E N EEDS

DI A GN O S T I C: REVI EW CU RREN T

PRA CT I CES .

BEN CH M A RKI N G: S U M M A RI S E A N D

CO M PA RE BES TPRA CT I CES .

EN LI GH T EN &I M PLEM EN T

DEFI N ERES PO N S I BI LI T I ES :

W H Y, W H A T & H O W

RECO GN I T I O N . RECO GN I S E T H E CO N T RI BU T I O N O F O T H ERS .

EVA LU A T E &VA LI DA T E

PILOT TRAININGPROGRAM

FEEDBACK

CO RRECT &S T A N DA RDI S E

REVI EW F EEDBA CK &M A KE CO RRECT I O N S

S T A N DA RDI S E DO ,CH ECK, A CT

Purpose:- To monitor effect of implementation of project plan & find Countermeasures to further improve the solution.

I N VES T I GA T E

DET ERM I N E N EEDS

DI A GN O S T I C: REVI EW CU RREN T

PRA CT I CES .

BEN CH M A RKI N G: S U M M A RI S E A N D

CO M PA RE BES TPRA CT I CES .

EN LI GH T EN &I M PLEM EN T

DEFI N ERES PO N S I BI LI T I ES :

W H Y, W H A T & H O W

RECO GN I T I O N . RECO GN I S E T H E CO N T RI BU T I O N O F O T H ERS .

EVA LU A T E & VA LI DA T E

PILOT TRAININGPROGRAM

FEEDBACK

CO RRECT &S T A N DA RDI S E

REVI EW F EEDBA CK &M A KE CO RRECT I O N S

S T A N DA RDI S E DO ,CH ECK, A CT

Purpose:- To Review Continuously the Performance Measure & make adjustments as required. Integrate new situation into Normal Working Practice. Start PDCA Cycle again.

Problem Solving ProcessProblem Solving ProcessPLAN

◦ Step 1 : Identify the Problem

◦ Step 2: Analyze the problem

DO◦ Step 3: Develop

Solutions◦ Step 4: Implement

a Solution

CHECK◦ Step 5: Evaluate

the Results

Do you achieve your desired goal?

ACT◦ Step 6:

Standardize the solution

A3 Reporting ToolA3 Reporting Tool• Is 11 x 17 paper which is big

enough for the required information but allows you to keep it on 1 page

• Is a living document; use it at every step

• Write in PENCIL – you won’t cheat with smaller font sizes and it encourages you to draw pictures to describe the issue and improvement

Information should flow and Information should flow and be simplebe simple

PLAN

Background (What is the issue?)

AndBusiness Case (Why are

you doing this?)

Target Condition

Current ConditionSteps,

Conditions,And Measurements

Important TipsImportant TipsProblems can stem from over

planning or under planning—important to find the right PDCA balance -- A decade to learn to “Plan,” a decade to learn to “Do” . . .

Constrained resources can lead to a lot of doing, and not much else

Documentation is key to PDCA, so that knowledge can be recorded and internalize

PDCA ExercisePDCA ExerciseDivided into your teamsReceive a deck of cards.Do not touch the cards till told to

do so.Run three timesEach time :

◦Divide the cards evenly among your team members according to point value

11stst Run RunOne person pick up the deck and

shuffle the cards.Point value

◦Ace 1 point◦2 2 points◦3 3

◦4 4◦5 5◦6 6◦7 7◦8 8◦9 9◦10 10

DID YOU GET ALL THE CARDS DID YOU GET ALL THE CARDS

DIVIDED EVENLY TO YOUR TEAM DIVIDED EVENLY TO YOUR TEAM

MEMBERS?MEMBERS?

GO!

STOP!

22ndnd RunRun

Collect the cards and shuffle the deck.

Place it face down on the table. Do not touch it till told to do so

Plan how your team will divide up the cards evenly based on the points. You have 5 minutes.Point valueAce 1 point2 2 points3 3 points

4 4 points5 5 points6 6 points7 7 pts8 8 pts9 9 pts10 10 pts

DID YOU GET ALL THE CARDS DID YOU GET ALL THE CARDS

DIVIDED EVENLY TO YOUR TEAM DIVIDED EVENLY TO YOUR TEAM

MEMBERS?MEMBERS?

GO!

STOP!

LasLast t RuRunn

Collect the cards and shuffle the deck.Place it face down on the table. Do not

touch it till told to do soCheck how your team can improve

your plan to divide up the cards evenly based on the points. You have 5 minutes.

Point valueAce 1 point2 2 points3 3 points

4 4 points5 5 points6 6 points7 7 pts8 8 pts9 9 pts10 10 pts

DID YOU GET ALL THE CARDS DID YOU GET ALL THE CARDS

DIVIDED EVENLY TO YOUR TEAM DIVIDED EVENLY TO YOUR TEAM

MEMBERS?MEMBERS?

GO!

STOP!

ANY QUESTIONS?ANY QUESTIONS?