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PDCA Plan Do Check Act

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PDCA Process Improvement

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PDCA Plan Do Check Act

  1. 1. Plan-Do-Check-Act (PDCA)
  2. 2. Outline  What is PDCA ?  Background  Phases of PDCA  When to Use Plan–Do–Check–Act  Case Study  Benefits of PDCA
  3. 3. What is PDCA?  PDCA stands for Plan-Do-Check-Act [1]  Iterative four-stage model for continuous improvement (CI)  It teaches organizations to • PLAN an action • DO it • CHECK it • ACT on it [1].http://whatis.techtarget.com/definition/PDCA-plan-do-check-act
  4. 4. What is PDCA?[1]  Implementing New Ideas in a Controlled Way  It is also known as • plan–do–check–adjust • Deming circle/cycle/wheel • Shewhart cycle, control circle/cycle • or plan–do–study–act (PDSA) [1].http://whatis.techtarget.com/definition/PDCA-plan-do-check-act
  5. 5. Background  Walter Shewhart (1920’s) Shewhart Learning and Improvement cycle [2]  W. Edwards Deming (1950’s) [2]  It is a combination of management thinking with statistical analysis  Japanese translation into English became PDCA. [3]https://www.isixsigma.com/dictionary/deming-cycle-pdca/ [2]https://www.ncbi.nlm.nih.gov/pmc/articles/PMC2464836/
  6. 6. PDCA – Overview Plan Do Check AchievedNo Modify parameters goal? Yes Act Another problem or improvement [1].http://whatis.techtarget.com/definition/PDCA-plan-do-check-act
  7. 7. Four Phases of PDCA [5]  Plan a change aimed at improvement  Do – Carry out the change  Check/Study the results  Act - Adopt, adapt, or abandon [5]www.yourarticlelibrary.com/business/continuous-business-process...4-phases/21128/
  8. 8. PLAN Analyze current condition Identify exactly what your problem is Map the process Establish the objectives [5]www.yourarticlelibrary.com/business/continuous-business-process...4-phases/21128/
  9. 9. DO  Implement the plan  Generate possible solutions  execute the process  make the product.  Collect data for charting and analysis in the following "CHECK" and "ACT" steps. [5]www.yourarticlelibrary.com/business/continuous-business-process...4-phases/21128/
  10. 10. Check/Study  Study the actual results (measured and collected in "DO" above)  Compare  Against the expected results [5]www.yourarticlelibrary.com/business/continuous-business-process...4-phases/21128/
  11. 11. Act  Take action based on what you learned in the study step  Two Possibilities 1. If the change did not work, go through the cycle again with a different plan. 2. If you were successful then standardize. [5]www.yourarticlelibrary.com/business/continuous-business-process...4-phases/21128/
  12. 12.  As a model for continuous improvement.  When starting a new improvement project.  When developing a new or improved design of a process, product or service.  Exploring a range of possible new solutions to problems When to Use Plan–Do–Check–Act?[7] [7]http://asq.org/learn-about-quality/project-planning-tools/overview/pdca-cycle.html
  13. 13.  When defining a repetitive work process.  When planning data collection and analysis in order to verify and prioritize problems or root causes.  When implementing any change.  Avoiding the large scale wastage of resources that comes with full scale implementation of poor solution. When to Use Plan–Do–Check– Act? [7]http://asq.org/learn-about-quality/project-planning-tools/overview/pdca-cycle.html
  14. 14. A Case Study Maroco (Supplier of: Leather Goods, leather items )  About Company • Production unit under study • Located in northern Portugal, • Famous on the Production of leather components for leather goods [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  15. 15. Quality Management Methodology  Three Stages of Quality Management • Assessment of quality management processes • General quality data analysis • The application PDCA cycle (to solve a specific problem that was considered a priority in the previous step [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  16. 16. Production system of Functional Sections  It is organized into three functional sections • cutting (raw material (leather) is cut giving rise to various components); • preparation (components undergo various operations, including, uniformity and reduction of leather thickness, pressing, bonding, molding and painting); • assembly (components are assembled to form the end product, through sewing operations). [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  17. 17.  In Quality Assessment Process we evaluate that we are following the quality Processes or not like Quality Planning, Quality Control and Quality Improvement  By Analyzing Historical Data we found the defects section e.g. The average number of nonconforming components in the preparation section is 3.5%. Similarly, the average number of nonconforming components in the assembly section was 2.1% of defective components.  PDCA Quality Improvement Process used to solve the Quality Problem PDCA Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  18. 18. Plan  In Plan phase causes of the problem were analyzed and an action plan was established  The problem identified in preparation section, it was related to the nonconforming components e.g. thinning of the leather, that were detected in process and which led to several complaints from customers. • The thickness of the component is outside the specification limits of 0.40 ± 0.05 mm; [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  19. 19.  Brainstorming sessions were performed in regular meetings to identify the possible causes of the problem and build the action plan. e.g. Replacement of the measuring instrument, the implementation of the optimum combination of parameters for the equalization machine [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  20. 20. DO & Check  Do Phase  After formulating the action plan it was necessary to implement it, by acting on the processes.  Our plan is to increased the machine blades sharpness  Check Phase  After the Plan and Do steps, the Check step was carried out to evaluate the effectiveness of the actions. E.g. In this case study The average production of nonconforming components decreased from about 0.40% to 0.20%.  If we don’t achieve effective result then we again perform the Improvement process till that we get the effective result [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  21. 21. Act  Act Phase  The last step of the PDCA cycle is based on the standardization of the actions in which effectiveness was observed in the Check step.  Result [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013.
  22. 22. Benefits of PDCA  Effective and rapid method for implementing continuous improvement.  Minimizes Cost  Built-in Check  Expandable  standardized method  Fosters teamwork
  23. 23. Comparison: Benchmarking GQM Root Cause Analysis PDAC For Both Software and Hardware. For Software only. For Both Software and Hardware. For Both Software and Hardware Requires data from peers. Does not require data. Does not require data. Require Previous data Does not tell the relation between cause and effect. Does not tell the relation between cause and effect. Tells the relation between cause and effect. Tell the relation ship Flowchart, cause effect diagram also used in PDCA
  24. 24. References [3]https://www.isixsigma.com/dictionary/deming-cycle-pdca/ [2]https://www.ncbi.nlm.nih.gov/pmc/articles/PMC2464836/ [1].http://whatis.techtarget.com/definition/PDCA-plan-do-check-act [4]www.change-management-consultant.com/deming-cycle.html [5]www.yourarticlelibrary.com/business/continuous-business- process...4-phases/21128/ [6]www.brighthubpm.com › Methods and Ideologies [8]Fábio A. Fernandes, Sérgio D. Sousa, Member, IAENG and Isabel Lopes , “On the Use of Quality Tools: A Case Study ”, Journal of World Congress on Engineering July 3-5, 2013. [7]http://asq.org/learn-about-quality/project-planning- tools/overview/pdca-cycle.html

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