Continuous Improvement Toolkit Implement the Best Solution Identify your Problem Study Results Test Potential Solutions Plan – Do – Check/Study – Act A framework for problem solving , continuous improvement and change Widely recognized as the basis of continually improving the quality of Process , Product & Services An easy to remember four logic sequence steps : Plan – Do – Check /Study – Act Provides a simple and structured approach for solving quality –related problems Multiple iterations of the PDCA cycle 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 Often used when :- --- Intending to make minor changes to the process --- The solution to the problem is known Repeating the PDCA cycle frequently will help implementing KAIZEN and other continuous improvement initiatives Following are based around the PDCA philosophy – TQM , ISO standards , A3 thinking process The team selects the problem to be solved (process to be improved) The Problem and Objective are clearly identified The current situation is analyzed Solutions alternatives are identified , selected and scheduled The solution is tested on a small scale basis It involves collecting data for later analysis It also involve measure progress Its ensures the solution is appropriately tested and benefits are validated before committing to full implementation Involves analyzing the collected data comparing the actual results against the planned objectives Allows evaluating how well the solution worked Allows discussing whether further improvements are possible Concerned with identifying unexpected issues , their cause , & gathering , summarizing the key learnings Involves acting on the feedback and lessons learned and implementing the solution fully It is also concerned with- Standardizing Documenting Sustain the improved process Integrating it into the organizations system Gap Analysis ,Fault Tree Analysis ,Waste Analysis , Brainstorming ,Process Mapping etc. Gantt Charts , on-the-job training , conflict resolution , data collection methods , sampling , control charts etc. Graphical analysis , Cause and Effect analysis , statistics , Pareto analysis , Group decision-making technique etc. Gantt charts , check sheets , control chart , control planning standard work procedure

1. Quality Journey by Nilesh Jajoo
Quality Journey
Session -2 PDCA

2. Quality Journey by Nilesh Jajoo
Continuous Improvement Toolkit
Plan – Do – Check/Study – Act
Identify your
Problem
Test Potential
Solutions
Study
Results
Implement the Best
Solution

3. Quality Journey by Nilesh Jajoo
PDCA
• A framework for problem solving , continuous improvement and change
• Widely recognized as the basis of continually improving the quality of Process , Product & Services
• An easy to remember four logic sequence steps :
Plan – Do – Check /Study – Act
• Provides a simple and structured approach for solving quality –related problems
• Multiple iterations of the PDCA cycle 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
• Often used when :-
--- Intending to make minor changes to the process
--- The solution to the problem is known
• Repeating the PDCA cycle frequently will help implementing KAIZEN and other continuous
improvement initiatives
• Following are based around the PDCA philosophy – TQM , ISO standards , A3 thinking process

4. Quality Journey by Nilesh Jajoo
PDCA
Plan Do Check Act
• The team selects the
problem to be solved
(process to be
improved)
• The Problem and
Objective are clearly
identified
• The current situation
is analyzed
• Solutions alternatives
are identified ,
selected and
scheduled
• The solution is tested
on a small scale basis
• It involves collecting
data for later analysis
• It also involve measure
progress
• Its ensures the
solution is
appropriately tested
and benefits are
validated before
committing to full
implementation
• Involves analyzing the
collected data
comparing the actual
results against the
planned objectives
• Allows evaluating how
well the solution worked
• Allows discussing
whether further
improvements are
possible
• Concerned with
identifying unexpected
issues , their cause , &
gathering , summarizing
the key learnings
• Involves acting on the
feedback and lessons
learned and
implementing the
solution fully
• It is also concerned with-
1. Standardizing
2. Documenting
3. Sustain the improved
process
4. Integrating it into the
organizations system

5. Quality Journey by Nilesh Jajoo
Useful Tools
Act
Check
Do
Plan Gap Analysis ,Fault Tree Analysis ,Waste Analysis , Brainstorming ,Process Mapping
etc.
Gantt Charts , on-the-job training , conflict resolution , data collection methods ,
sampling , control charts etc.
Graphical analysis , Cause and Effect analysis , statistics , Pareto analysis , Group
decision-making technique etc.
Gantt charts , check sheets , control chart , control planning standard work procedure

6. Quality Journey by Nilesh Jajoo