PDCA.pdf

PDCA Cycle

1. PDCA Cycle | Plan
Do Check Act |
Implementation

2. PDCA CYCLE
2
FREE
TUTORIAL

3. What is the PDCA cycle in TQM?
3
ThefullnameisthePlan-Do-Check-ActCycleanditisoneofthepopularProblem
SolvingMethodandContinuousImprovementMethodology.
ItisoftenreferredtoastheDemingwheelorDemingcycle.
ShewhartandDemingarerecognizedaspioneersintheQualityManagement
movement.
ShewhartintroducedthePDSAcycle,(Plan-Do-Study-Act).
Hebelievedthatdataanalysisisanessentialpartofanyimprovementeffortand
checkingdoesnotnecessarilyimplyanin-depthstudy.

4. What is the PDCA model of
continuous improvement?
4
PDCAiswidelyrecognizedasthebasisofcontinuallyimprovingtheQualityof
Productsprocesses,andservicesandalsoitisasimplestructuredapproach
forsolvingquality-relatedproblems.Itmaybenecessarytosolvetheproblem
permanentlyandreachtheultimategoalstate.
Usedtoverifythefeasibilityofaproposedideawhetheritisanincrementalora
breakthroughimprovement.
Plan-Do-Check-ActapproachisthebaseforTQM,ISO9001:2015Quality
ManagementSystemStandard,A3thinkingmethodology,andIATF
16949:2016AutomotiveQMSStandard.
Thismethodologyreliesontrialanderror,however,itkeepsonimprovinguntil
itachievesexcellence.
ItisoneofthemostpopularLeanManufacturingToolacrossthemanufacturing
industries.

5. Continuous Improvement Cycle
5

6. What are the four steps in the PDCA
cycle?
6
1.Plan–Achangeaimedatimprovement
2.Do–Carryoutthechange
3.Check–Studytheresults
4.Act–Adopt,Adapt,orAbandon

7. Four Phases of PDCA Cycle
7

8. How to Implement the PDCA Cycle?
Example:
Implementation of Plan Phase:
8
There are four sub-phases are available in the planning phase which is explained
below in sequence:
1.Select Improvement Opportunity
2.Analyze Current Situation
3.Identify Root Causes
4.Generate and Choose Solution

9. [1] Select Improvement Opportunity:
9
Generate a list and select
Redefine team
Write problem / opportunity / aim statement
Describe the problem
Management review
The team selects the problem to be solved (to be improved)
The problem and objectives are clearly identified
The current situation is analyzed.
Solution alternatives are identified, selected and scheduled

10. [2] Analyze Current Situation:
10
Define the process/problem to be solved
Identify the customer(s).
Prepare Baseline data
Check any Performance gaps are available?
Look at benchmarks, standards, regulatory requirements
Validate problem and statement
Management review

11. [3] Identify Root Causes:
11
This is a very veryimportant step
Utilize the Cause and Effect Diagram (Fishbone Diagram or Ishikawa Diagram, or Why-
Why analysis to identify the most likely cause(s).
Use GenchiGembutsuMethod
Select root cause
Management review

12. [4] Generate and Choose Solutions:
12
Generate a list and select solutions
Directly linked to root cause & supported by data
Team brainstorming and shared decision making
Be honest about barriers
Choose the best solution based on criteria
Define and map out a solution
Develop solution(s) to remove the root cause(s)
Select the best solution(s) to remove the root cause(s)
Verify that effectiveness of the selected solutions
Verify that selected solutions do not cause any undesirable effects
Set a Target that you want to achieve

13. Implementation of Do Phase:
[5] Map Out and Implement a Trial Run:
13
Map out a trial run
Communication and education/training are key factors
Be specific
Implement a trial run
Ensure all the countermeasures are completed
It involves collecting data for later analysis
It ensures the solution is appropriately tested
Implementation of Check Phase:
The check phase has two sub-phases which are mentioned below.
6.Analyze the Results
7.Draw Conclusions

14. [6] Analyze the Results:
14
Evaluate results based on collected data
Team-based analysis
Objective and subjective data
Revisit the process as it was mapped out
Be honest!
Evaluate both Results and Process
Involves analyzing the collected data and comparing the actual results against the
planned objectives.
Allows discussing whether further improvements are possible
You may have to repeat the Do and Check a number of times until you get the optimum
results

15. [7] Draw Conclusions:
15
Team-based discussion
Was the root cause eliminated?
What worked?
Did the desired change occur?
What didn’t work?
What could be improved/changed?
Implement the best solution(s) to remove the root cause(s)
What did we learn?
Implement the best solution(s) to address the escape point(s)
Validate the effectiveness of the implemented solutions by Customer's perspective
Monitor the effectiveness of the implemented solutions and assure that they do not
cause any undesirable effects
Remove Interim Containment Actions
Implementation of Act Phase:
The last phase is the act phase and it has two sub-phases as mentioned below.
8.Adopt, Adapt, or Abandon the Intervention
9.Monitor; Hold the gains

16. [8] Adopt, Adapt, or Abandon the
Intervention:
16
Team-based discussion and beyond
Test again on a larger scale?
Communication, education, and training
Revise plan and repeat trial
Communication, education, and training
Revisit root cause analysis and/or list of solutions
Need additional/new members on the team?
Involves acting on the feedback and lessons learned and implementing the solution
It is also concerned with: Standardizing, Documenting, Sustaining the improved
process
Integrating it into the organization’s system.

17. [9] Monitor; Hold the gains:
17
Standardize the change
Change to department policy?
Continue to monitor improvement
Same data collection tools and process
Continue reporting to staff and management
Move to new improvement opportunity
Standardize Success and Learn from Failures

18. Useful Tools for PDCA Cycle:
18
There are several useful tools of the PDCA Cycle is mentioned in the below picture.

19. What are the benefits of the PDCA
cycle?
19
•PDCA approach encourages the way of problem-solving and implementing solutions
•PDCA (Plan-Do-Check-Act) approach ensures that you plan, test, and include
feedback before you start full-scale implementation
•Repeating the PDCA_Cycle frequently will help to implement Kaizen and other
continuous improvement initiatives.
•PDCA_approach brings you closer to your goals as knowledge is increased: from
solving problems, from failures, from the feedback received.
•This approach Improves the critical thinking skills of your team

20. THANKS!
Any questions?
You can find me at:
⦿@username
⦿[email protected]
20