PDCA/A3

Introduction 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.
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).
 ACT PLAN

Customer
Satisfaction

CHECK DO

PL
AN
T

I NVESTI GATE
C

CORRECT &
A

STANDARDI SE CLARI FY OBJECTI VES

Ÿ REVI EW FEEDBACK & I DENTI FY POSSI BLE CAUSES

MAKE CORRECTI ONS
BENCHMARK BEST PRACTI CE
Ÿ STANDARDI SE DO,
CHECK, ACT I DENTI FY TEAM ROLES

I MPLEMENT QUI CK FI X

EVALUATE & VALI DATE ENLI GHTEN &

I MPLEMENT
PILOT STUDY SOLUTION
TO VERIFY DATA CARRY OUT TRI ALS TO
PROVE CAUSES
COUNTERMEASURE
ANALYSE DATA TO

CH TRAINING
UNDERSTAND HOW
PROBLEM OCCURS

EC COMMUNICATION I DENTI FY POSSI BLE

O
SOLUTI ONS

D
 Purpose:- To INVESTIGATE the

PL
T
AC

A
I N VEST I GAT E

current situation & understand fully

CORRECT &
ST AN DARDI SE DETERMI NE NEEDS

N
Ÿ REVI EW FEEDBACK & Ÿ DI AGNOSTI C:
MAKE CORRECTI ONS Ø REVI EW CURRENT

the nature of the problem being

PRACTI CES.
Ÿ STANDARDI SE DO,
CHECK, ACT Ÿ BENCHMARKI NG:
Ø SUMMARI SE AND
COMPARE BEST
PRACTI CES.

EVALUAT E & VALI DAT E

Ÿ PILOT TRAINING
PROGRAM
EN LI GHT EN &
I MPLEMEN T

Ø DEFI NE
solved.
RESPONSI BI LI TI ES:
Ÿ FEEDBACK W HY, W HAT & HOW

Ø RECOGNI TI ON.
RECOGNI SE THE
C

DO
CONTRI BUTI ON OF
H

OTHERS.
E
C
K

PLA
N Purpose:- To Enlighten the
T

I N VEST I GAT E
C

CORRECT &
A

ST AN DARDI SE DETERMI NE NEEDS

Ÿ
REVI EW FEEDBACK &
MAKE CORRECTI ONS

STANDARDI SE DO,
Ÿ
Ø
DI AGNOSTI C:
REVI EW CURRENT
PRACTI CES.
Team as to the Real Problem by
Ÿ

analysing the Data and defining

CHECK, ACT BENCHMARKI NG:
Ø SUMMARI SE AND
COMPARE BEST
PRACTI CES.

EVALUAT E & VALI DAT E EN LI GHT EN &

Ÿ
PILOT TRAINING
PROGRAM

FEEDBACK
I MPLEMEN T

Ø DEFI NE
RESPONSI BI LI TI ES:
W HY, W HAT & HOW
and implementing a solution
CH
EC
Ø RECOGNI TI ON.
RECOGNI SE THE
CONTRI BUTI ON OF
OTHERS.
plan.
K
O
D
Purpose:- To monitor effect of PLA
N

T
I N VEST I GAT E

C
CORRECT &

implementation of project plan

A
ST AN DARDI SE DETERMI NE NEEDS

Ÿ REVI EW FEEDBACK & Ÿ DI AGNOSTI C:

MAKE CORRECTI ONS Ø REVI EW CURRENT
PRACTI CES.

& find Countermeasures to

Ÿ STANDARDI SE DO,
CHECK, ACT Ÿ BENCHMARKI NG:
Ø SUMMARI SE AND
COMPARE BEST
PRACTI CES.
EVALUAT E & EN LI GHT EN &

further improve the solution. CH VALI DAT E I MPLEMEN T

Ÿ PILOT TRAINING Ø DEFI NE

PROGRAM RESPONSI BI LI TI ES:

EC
W HY, W HAT & HOW
Ÿ FEEDBACK
Ø RECOGNI TI ON.
RECOGNI SE THE
CONTRI BUTI ON OF

O
OTHERS.

D
Purpose:- To Review PLA

T
I N VEST I GAT E N

C
Continuously the Performance CORRECT &
ST AN DARDI SE DETERMI NE NEEDS

A
Ÿ REVI EW FEEDBACK & Ÿ DI AGNOSTI C:
MAKE CORRECTI ONS Ø REVI EW CURRENT

Measure & make adjustments

PRACTI CES.
Ÿ STANDARDI SE DO,
CHECK, ACT Ÿ BENCHMARKI NG:
Ø SUMMARI SE AND
COMPARE BEST
PRACTI CES.

as required. Integrate new EVALUAT E & VALI DAT E

Ÿ PILOT TRAINING
PROGRAM
EN LI GHT EN &
I MPLEMEN T

Ø DEFI NE
RESPONSI BI LI TI ES:

situation into Normal Working CH

Ÿ FEEDBACK

Ø
W HY, W HAT & HOW

RECOGNI TI ON.
RECOGNI SE THE

EC CONTRI BUTI ON OF
OTHERS.

Practice. Start PDCA Cycle K

O
D
again.
Problem Solving Process
 PLAN  CHECK
◦ Step 1 : Identify the ◦ Step 5: Evaluate the
Problem Results
◦ Step 2: Analyze the
problem Do you achieve your
 DO desired goal?
◦ Step 3: Develop
Solutions  ACT
◦ Step 4: Implement a ◦ Step 6: Standardize the
Solution solution
 A3 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 be
simple
PLAN
Target Condition
Background (What is the issue?)
And
Business Case (Why are you
doing this?)

Steps,
Current Condition Conditions,
And Measurements
Important Tips
 Problems 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 Exercise
 Divided into your teams
 Receive a deck of cards.
 Do not touch the cards till told to do so.
 Run three times
 Each time :
◦ Divide the cards evenly among your team
members according to point value
 One person pick up the deck and shuffle
1st Run 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
GO!

STOP!
DID YOU GET ALL THE CARDS DIVIDED
EVENLY TO YOUR TEAM MEMBERS?
  Collect the cards and shuffle the deck.
2nd Run
 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 value
Ace 1 point
2 2 points
3 3 points
4 4 points
5 5 points
6 6 points
7 7 pts
8 8 pts
9 9 pts
10 10 pts
GO!

STOP!
DID YOU GET ALL THE CARDS DIVIDED
EVENLY TO YOUR TEAM MEMBERS?
  Collect the cards and shuffle the deck.
Last
 Place it face down on the table. Do not
Run
touch it till told to do so
 Check how your team can improve your
plan to divide up the cards evenly based
on the points.You have 5 minutes.
Point value
Ace 1 point
2 2 points
3 3 points
4 4 points
5 5 points
6 6 points
7 7 pts
8 8 pts
9 9 pts
10 10 pts
GO!

STOP!
DID YOU GET ALL THE CARDS DIVIDED
EVENLY TO YOUR TEAM MEMBERS?
ANY QUESTIONS?