1 - How To PDCA - Plan Do Check Act 20191019

PDCA - Plan Do Check Act
New PDCA？Want to be CAO?
Rebecca Cai | AutoChina

WeChat：autochinarebecca
汽车中国 | 蔡懿
微信：autochinarebecca
1
Email: auto.china@outlook.com
Purpose
•To fully understand of the Plan-Do-Check-Act
process and how it applies to our daily business
processes in Manufacturing.
•To recognize the key steps in effectively executing
the PDCA process.
•To understand the PDCA Process and it’s
relationship to the Continuous Improvement cycle
and the 5-Step Improvement Process.
2
When to use the PDCA Process?
• New Projects/ Activities

• Annual Plan and Monthly Reviews (BPD)
• Problem Solving
• When Performance to SQDCM Objectives are
not being met and become RED

3
When to use the PDCA Process?

• As part of the 5 Step Improvement Process

4
History
This methodology was originally called the “Shewhart Cycle” after its
founder, Walter Shewhart, but was renamed in 1950 for W. Edwards
Deming.
Description
Design Also known as the Continuous Improvement Cycle
Is a standardized problem solving procedure
Plan: what should be done
Do: implement the plan
Check: verify the result
Act: correct problems that arise; document;
Research
standardize; if goal is not achieved, repeat the process.
Production
Benefits
Provides a standard template for how people should
approach problems and improvements
The PDCA Process is a simple methodology for
Sales approaching Continuous Improvement.

5
PDCA = Plan
The PLAN phase consists of 5 Steps:
1. Study the Current State situation.
2. Identify an opportunity for improvement.
3. List tasks/steps necessary for achieving
improvement.
4. Prioritize.
5. Identify means for measuring progress on tasks.
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1. Study the Current State Situation

PDCA: How to plan the “Plan”...
• Grasp the “big picture” before focusing on
specific problems.
• Describe the current process surrounding
the improvement opportunity.
• Avoid relying on opinion by going to see
what is actually occurring.
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2. Identify an Opportunity for Improvement

• Frame the improvement opportunity in
quantifiable terms.
• Describe all the possible causes of the
improvement opportunity and get to the
root cause.

8
3. List Tasks/Steps Necessary for Achieving Improvement

• Ask yourself, “What tasks must I perform
to implement improvement?”
• What steps are necessary to perform each
task?
• List those tasks/steps.

9
4. Prioritize

• Review the tasks/steps you listed in Step 3 and
prioritize them from highest to lowest, using a
number scale
• Priorities should be based on cost, effort, and
benefit decision analysis

10
5. Identify Means for Measuring Progress on Tasks

• After prioritizing the tasks/steps necessary for
improvement, decide what tool you will use to
measure each task/step.
• The measurement should answer the
question… How will we know when the task has
been successfully completed?
11
PDCA = Plan (Summary)

The PLAN phase consists of 5
Steps:
1. Study the Current State Situation.
2. Identify an opportunity for
improvement.
3. List tasks/steps necessary for
achieving improvement.
4. Prioritize.
5. Identify means for measuring
progress on tasks.

12
PDCA = DO
The DO phase is the implementation of the

PLAN; it consists of 4 Steps:
1. Create a timeline for each step/task
2. Monitor the timeline and its milestones for progress
3. Support the participants who are conducting the
steps/tasks
4. Review the completion status of the plan

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1. Create a Timeline for Each Step/Task

PDCA: How to do the “Do”... I better get
moving if I’m
• Use a Gantt chart or bar going to meet
graph as a timeline to my deadline!
identify key milestones in
the improvement process.
• Clearly Communicate to all
who will support the plan.

14
2. Monitor the Timeline and its Milestones for Progress
PDCA: How to do the “Do”... That task

was supposed
• Each step/task should to be done
yesterday!
have a specific person or
persons assigned to
monitor the improvement
progress and timeline
status

15
3. Support the Participants Who are Conducting the Steps/Tasks
PDCA: How to do the “Do”...

• Those who support each I’m here
to support
task must define the “what,” you!
not the “how.”
• Function as a mentor.
• Follow through is key.

16
4. Review the Completion Status of the Plan
PDCA: How to do the “Do”... Great job

meeting your
• Review the status of the deadlines!
steps/task against the completion
date.
• Is the team on track? Are those
responsible for task
implementation doing their work?

17
PDCA = DO (Summary)
The DO phase is the
implementation of the PLAN;
it consists of 4 Steps:
1. Create a timeline for each
step/task.
2. Monitor the timeline and its
milestones for progress.
3. Support the participants who
are conducting the
steps/tasks.
4. Review the completion status
of the plan.
18
PDCA =Check
The CHECK phase monitors the progress of the PLAN and

determines if modifications are required. There are 3 Steps in
the CHECK phase.
1. Measure the progress and results for each task.

2. Evaluate the results at task completion.
3. Confirm desired results were achieved

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1. Monitor the Progress and results for Each Task
PDCA: How to check the “Check”...

• Build checkpoints into the process.
• Monitor progress on each and all tasks.
• Provide timely advice before things go astray.
• Checking should be a positive way to show
interest and support.
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2. Evaluate the Results at Task Completion
• Assess progress in quantifiable terms.

• Assess impact on task measurable.
• Evaluate process for completing tasks.

21
3. Confirm Desired Results were Achieved
• Assess impact on measurable.

• On schedule, on target, on budget, on
purpose, and is it practical?

22
PDCA =Check (Summary)

The CHECK phase monitors
the progress of the PLAN and
determines if modifications are
required. There are 3 Steps in
the CHECK phase.
1. Measure the progress and

results for each task.
2. Evaluate the results at task
completion.
3. 3. Confirm desired results
were achieved.
23
PDCA =Act
The ACT phase is the implementation of the
final plan to ensure that the improvements are
standardized and practiced continuously. This
leads back to the PLAN stage for further
diagnosis and improvement. There are 2 Steps
to the ACT stage.
1. Reflect on “Lessons Learned.”
2. Plan the “Next Steps.”
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1. Reflect on Lessons Learned
PDCA: How to ACT and reACT

• Evaluate the Check phase results and list issues,
problems, and barriers encountered throughout
the PDCA Process.
• Standardize effective action
• Avoid ineffective actions

25
2. Plan the Next Steps
PDCA: How to ACT and reACT

• Assess results.
• Recommend changes.
• Determine the next level of improvement.
• Continue the improvement process by
starting a new PDCA process.

26
PDCA =Act(Summary)
The ACT phase is the
implementation of the final plan
to ensure that the
improvements are standardized
and practiced continuously. This
leads back to the PLAN stage
for further diagnosis and
improvement. There are 2
Steps to the ACT stage.

2. Plan the “Next Steps”
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Act Leads to Plan

• When listing the
“Next Steps” in the
ACT phase, you are
actually listing the
tasks/steps for the
next PLAN phase.
• The process
continues or begins
again.

28
Summary
• Plan = 5 Steps
• Do = 4 Steps
• Check = 3 Steps
• Act = 2 Steps
PDCA = 1 Process

29
Review: PDCA and Continuous Improvement
• PDCA is an improvement cycle

A P
• Standardize effective practices
after each cycle C D
Improvements
• Continue the improvement

process by beginning another
cycle A P
C D
AP
CD
Time

30
PDCA and Business Plan

4 Next Phase of Action Plans 1 Annual Plan
Milestone
Milestone
s
s Milestone
s Milestone
s Milestone Items
Items
Itemss
Items
Items
A P
C
3 Evaluation of Process
D 2 Do the Plan
Milestone
Plan Do Ck Action sItems

Status
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Self Test: Define each phase of the PDCA

process and list the key steps
Defines in clear and simple terms the tasks required to implement improvement
PLAN 1. Study the Current State situation (set targets).
2. Identify an opportunity for improvement.
3. List tasks/steps necessary for achieving improvement.
4. Prioritize.
5. Identify means for measuring progress on tasks.
Executing an agreed upon plan
DO
1. Create a timeline for each step/task
2. Monitor the timeline and its milestones for progress
3. Support the participants who are conducting the steps/tasks
4. Review the completion status of the plan
CHECK Confirm the plan is properly implemented and achieves the desired results
1. Measure the progress and results for each task.
2. Evaluate the results at task completion.
3. Confirm final results
Institutionalize the improvement as a new standard

ACT
-Standardize
Rebeccawhat works,
Cai eliminate what doesn’t.
| AutoChina
- Prevent Re-occurrence and “read across” solutions
2. Plan the “Next Steps.”
32
Key Points
• PDCA is a process that supports a continuous improvement
philosophy.
• The CA (check act) portion of the process is equally as important as
the PD (Plan Do).
• During the Check phase we confirm the plan is properly implemented
and is achieving the desired results.
• The Action portion of the process has evolved to include steps on
preventing reoccurrence and institutionalizing the improvement as a
new practice to be improved upon.
• PDCA is a process through which new standards are set only to be
challenged again. Achieving standardization is not a fixed goal.

33

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PDCA - Plan Do Check Act

New PDCA？Want to be CAO?

Rebecca Cai | AutoChina

When to use the PDCA Process?

• New Projects/ Activities

Rebecca Cai | AutoChina

When to use the PDCA Process?

Rebecca Cai | AutoChina

Sales approaching Continuous Improvement.

1. Study the Current State Situation

2. Identify an Opportunity for Improvement

PDCA: How to plan the “Plan”...

Rebecca Cai | AutoChina

3. List Tasks/Steps Necessary for Achieving Improvement

PDCA: How to plan the “Plan”...

Rebecca Cai | AutoChina

PDCA: How to plan the “Plan”...

Rebecca Cai | AutoChina

5. Identify Means for Measuring Progress on Tasks

PDCA: How to plan the “Plan”...

PDCA = Plan (Summary)

Rebecca Cai | AutoChina

The DO phase is the implementation of the

Rebecca Cai | AutoChina

1. Create a Timeline for Each Step/Task

Rebecca Cai | AutoChina

2. Monitor the Timeline and its Milestones for Progress

PDCA: How to do the “Do”... That task

Rebecca Cai | AutoChina

3. Support the Participants Who are Conducting the Steps/Tasks

PDCA: How to do the “Do”...

Rebecca Cai | AutoChina

4. Review the Completion Status of the Plan

PDCA: How to do the “Do”... Great job

Rebecca Cai | AutoChina

The CHECK phase monitors the progress of the PLAN and

1. Measure the progress and results for each task.

Rebecca Cai | AutoChina

1. Monitor the Progress and results for Each Task

PDCA: How to check the “Check”...

2. Evaluate the Results at Task Completion

PDCA: How to check the “Check”...

• Assess progress in quantifiable terms.

Rebecca Cai | AutoChina

3. Confirm Desired Results were Achieved

PDCA: How to check the “Check”...

• Assess impact on measurable.

Rebecca Cai | AutoChina

PDCA =Check (Summary)

1. Measure the progress and

1. Reflect on Lessons Learned

PDCA: How to ACT and reACT

Rebecca Cai | AutoChina

2. Plan the Next Steps

PDCA: How to ACT and reACT

Rebecca Cai | AutoChina

1. Reflect on “Lessons Learned.”

Act Leads to Plan

Rebecca Cai | AutoChina

Rebecca Cai | AutoChina

Review: PDCA and Continuous Improvement

• PDCA is an improvement cycle

• Continue the improvement