Quality Circle Methodology

Learning Objectives

• Learn about quality circle methodology

• Understand the different steps in the
PDCA (continuous improvement) cycle
• Learn how to apply the steps to solve
real world problems
 Why use PDCA?
Human nature vs. Process
Jump straight to solution mode Allow time to plan

Fight the fires every time A structured approach

to defining the problem

No common understanding
of the real problem Involve the right people

No measure if the solution Test and monitor solutions

is a real success
to ensure goals are met
Using a systematic problem solving
process

• Plan

A P • Do

• Check

• Action
C D

Aim is continuous improvement

 Techniques to use with
PDCA
• Brainstorming • Affinity diagram
• Check sheet • Force field
• Cause and effect analysis
diagram • Run charts
• Pareto diagram • Scatter diagram
• Histogram • Control charts
• Control chart • Lotus diagram
• Flow chart • Gantt Chart
• 5 Whys
 Plan
Step Stages Recommended tool

1 Identify Projects / Areas for 

Brainstorming
Improvement 
Affinity Diagram

2 Select a Project 
Decision Matrix

3 Plan the Project Milestones Milestone or Gantt Chart

4 Collect Facts and Data on the 

Flow Chart (basic)
Present Status 
Check Sheet (basic)

Pareto Diagram

Survey

Questionnaire

Interview

Observation

5 Analyse Facts and Data Graphs

- Graphs
- Histogram
 Plan
Step Stages Recommended tool

6 Set Target for Improvement Approach: SMART

7 Determine Possible Causes Cause and Effect Diagram

8 Determine Vital Causes Check Sheets

Pareto Diagram
Graphs and Charts
Scatter Diagram

9 Develop Alternative Solutions for Brainstorming

each Vital Cause

10 Select the Best Solution(s) Force-field Analysis

PDCA FOUR-PHASE PROBLEM SOLVING
PROCESS (EFFORT)

ACTION

CHECK

PLAN
DO
 DO
• This is the stage of pilot implementation. This is
where the team has the opportunity to test ideas
by putting them into practice. If teams have any
problems in trying to implement the ideas, they
should seek the assistance of management.
• Keep a careful record of what happens when the
team's proposals are implemented. Monitor the
progress closely, and collect the data needed.
• Remember, there may be "side-effects" to the
proposal which have not been anticipated, which
may be good or otherwise. Note these as well, as
they must be taken into account when assessing
the success of the team's proposal.
 CHECK

• This is the stage of evaluation where

the team members compare the
'Before and After' results to gauge the
extent of the improvements.
• The results are also compared with
targeted results to determine if the
objectives have been met.
 ACT
• If the trial implementation shows a significant
improvement in the situation, clearly the proposal has
been successful and deserves to be implemented.
• Standard Operating Procedures (SOP) will be
amended duly to accommodate the new method.
Working manuals should be updated, and information
on the new system should be disseminated across the
departments.
• This does not mean the end of the action process.
The new method must be monitored regularly so that
it can be improved further when possible.
 PDCA
Cycle Increasing
Quality Expectations
Assurance
 Problem Solving process
1. Identify projects/ areas for improvement.
2. Select a project.
3. Plan the project milestones.
4. Collect facts and data on the present status.
5. Analyse facts and data.
6. Set target for improvement.
7. Determine possible causes.
8.Determine vital causes.
9. Develop alternative solutions for each vital cause.
10. Select the best solution.
11. Plan the solution implementation.
12. Implement the solution.
13. Verify if solution works.
14. Look for counter-measures if no. If yes, standardise the process and improve
it.
PDCA exercise- Making
Human Graph
• Stand in ascending order, as per
your birthdays , behind the line
at the back of the room.
• You have 5 minutes for this
exercise.