LEAN Continuous Improvement

Plan – Do – Check – Act (Adjust) (PDCA)

What is it: PDCA is an iterative four step problem solving process used in the ongoing cycle of
continuous improvement by completing the “feedback loop.” A methodology used to analyze and
measure, to identify sources of variations that cause products to deviate from customer
requirements.
Benefits of PDCA:
 Problem solving process  Vendor development
 Daily routine management for  Human resources development
the individual and/or team  New product development
 Project management  Process trials
 Continuous development

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LEAN Continuous Improvement
Plan – Do – Check – Act (Adjust) (PDCA)

PLAN – DO – CHECK – ACT (Adjust)

 PLAN: Design or revise production/business process components to improve results
 DO: Implement the plan and measure its performance
 CHECK: Assess the measurements, monitor and evaluate the processes and results against
objectives and specifications and report the results to decision makers (i.e. study the
results).
 ACT: Decide on changes needed to improve the process and apply actions to the outcome
for necessary improvement. Review all steps (Plan, Do, Check, Act) and modify the process
to improve it before its next cycle of implementation.

PDCA
1. Identify Process Managers – Process Owners
2. Map the Process (hands on exercise)
3. Benchmark competitors and world class performers
4. Create a Future State Process Map
Plan 5. Develop a Specific Action Plan for communication, education, Kaizen
events – names and target dates
6. Assess and address the three critical factors: Skills, Structure,
Environment for success
1. Communicate the plan
2. Execute action plan with sense of urgency, starting with education,
Do then improvement actions
3. Deploy Lean skills and learn by doing
4. Expand the toolbox
1. Set Review Schedule
2. Compare metrics to gauge improvement
Check 3. See it. Walk the floor
4. Communicate progress and obstacles
5. Celebrate success and build momentum
1. Re-deploy resources where needed
Act (Adjust) 2. Cycle back to Plan and refine

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