PDCA

CYCLE
L1F18BSFT0030-REMAL
AURANGZEB
FOOD QUALITY MANGEMENT
PRSENTED TO: DR. SANABIL
YAQOOB
 PDCA CYCLE

• W. Edwards Deming Father of Quality

Management
• Plan do check and act
• Inspired by "plan, do, and see" model
• PDCA cycle
• Simple and effective method
• Designed to be utilized as a continuous
improvement cycle.
 PLAN
• The problem's definition
• The phenomenon is being studied
• the discovery of the causes
• Analyze the procedure
• a list of causes that should be prioritized
• The action plan is being developed
 DO
• The action plan is carried out
Acceptance of the action
• completion of the necessary training
• follow-up to the execution
CHECK
• The results and effectiveness of the
actions are verified
• comparison is done between before and
after the procedure
• state or efficacy of the executed plan
during the check stage.
• Among the questions you could ask is,
Was the desired outcome achieved?
What went wrong if the desired result
was not achieved?
 ACT
• Involves the adoption of excellent practices
• Standardization of actions ensures the correct execution of activities.
• It is possible to finish the PDCA after the actions to maintain the results have
been ensured.
• New cycle can be rotated.
• Makes it easier to improve the process over time.
• Review the solutions in light of the standards, take action, and document the
results
TO EXAMINE AND FIX THE PROBLEM
OF EXCESSIVE SAUCE LOSSES IN A
PROCESS BY ADOPTING THE PDCA
CYCLE
 BACKGROUND
• The PDCA Cycle was used to examine and solve the problem of high
sauce losses in a process that produces frozen meals in a food company
in Southern Brazil
• quantitative and qualitative approach
• the amount of lost sauce was weighed for the purpose of calculating
losses and conducting a survey of the status of the process indicators
• causes of the problem and their related solutions
• reduced sauce losses by 86.75 percent
 IMPLEMENTATION
• First quantify the amount of sauce that was lost during the packing stage
• Several types of sauce were collected and samples were weighed
• Overall weight of the lost inputs
• After defining the core causes of the hypotheses that had already been
verified and confirmed
• Validation
 PLAN
• The plan phase began to be executed through the collections made to
quantify the losses.
• The volumes collected through the bags were weighed
• A calculation was made
 To carry out the proposed actions

In the execution of the action plan

Counted on the suppliers, working together

DO the internal workforce of the company. 

Several tests of materials and equipment

were used

Better performance test and equipment were

evaluated and defined.
 CHECK
• The check phase began
• Where new measurements were taken to verify the current situation of the
problem raised
• The result from production indicator after improvment were compared
• These values survey of possible causes.
• Using the ishikawa diagram cause was determined.
 ACT PHASE
• In the Act phase all the effective actions were replicated to production line 1
• which had the same specifications, and consequently presented the same
problems as similar values of losses.
• The losses of sauce in the filling lines occurred by the dripping of the dosers
during the filling of one tray and another.
• These lost quantities of sauce were accumulated in gutters under the
container line and also on the floor
 DATA ANALYSIS
•  the amount of 0.4343 kg of lost sauce per hour
•  The unplanned stops had an average occurrence of 21.13 hours in the
months prior to the completion of the work.
• An unplanned stoppage of the line is required in order to perform hygiene
and remove excess sauce from equipment and the floor
 RESULT
• In the search for these improvements
• The large reduction in sauce losses in packaging lines allowed for
improved brainstorming of ideas on what the sources of the losses were
• Optimizing the survey of the actions and their correct implementations
• Both in the planning and execution phases of the plan, the selection of the
work team was critical.
 REFERENCES
• https://www.eaglepi.com/blog/the-importance-of-a-fat-analysis-machine-i
n-the-continuous-improvement-process-plan-do-check-act/
• https://www.semanticscholar.org/paper/ADOPTING-PDCA-TO-LOSS-R
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