3. What is the PDCA cycle in TQM?
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The full name is the Plan-Do-Check-Act Cycle and it is one of the popular Problem
Solving Method and Continuous Improvement Methodology.
It is often referred to as the Deming wheel or Deming cycle.
Shewhart and Deming are recognized as pioneers in the Quality Management
movement.
Shewhart introduced the PDSA cycle, (Plan-Do-Study-Act).
He believed that data analysis is an essential part of any improvement effort and
checking does not necessarily imply an in-depth study.
4. What is the PDCA model of
continuous improvement?
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PDCA is widely recognized as the basis of continually improving the Quality of
Products processes, and services and also it is a simple structured approach
for solving quality-related problems. It may be necessary to solve the problem
permanently and reach the ultimate goal state.
Used to verify the feasibility of a proposed idea whether it is an incremental or a
breakthrough improvement.
Plan-Do-Check-Act approach is the base for TQM, ISO 9001:2015 Quality
Management System Standard, A3 thinking methodology, and IATF
16949:2016 Automotive QMS Standard.
This methodology relies on trial and error, however, it keeps on improving until
it achieves excellence.
It is one of the most popular Lean Manufacturing Tool across the manufacturing
industries.
6. What are the four steps in the PDCA
cycle?
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1. Plan – A change aimed at improvement
2. Do – Carry out the change
3. Check – Study the results
4. Act – Adopt, Adapt, or Abandon
8. How to Implement the PDCA Cycle?
Example:
Implementation of Plan Phase:
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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:
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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:
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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:
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This is a very very important step
Utilize the Cause and Effect Diagram (Fishbone Diagram or Ishikawa Diagram, or Why-
Why analysis to identify the most likely cause(s).
Use Genchi Gembutsu Method
Select root cause
Management review
12. [4] Generate and Choose Solutions:
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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:
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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:
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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:
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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:
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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:
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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:
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There are several useful tools of the PDCA Cycle is mentioned in the below picture.
19. What are the benefits of the PDCA
cycle?
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• 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