Plan Do Check Act (PDCA) is a iterative four-stage model for continuous improvement involving planning a change, implementing it, evaluating the results, and acting on lessons learned. The document describes each stage of the PDCA cycle and provides an example of its use in a case study of a leather goods supplier to reduce defects. The case study demonstrated applying PDCA to identify causes of defects, implement a plan to sharpen machine blades, check the results showed reduced defects, and standardize the improvement.

1. PLAN DO CHECK ACT (PDCA)

2. NAME : PARTHO KUMAR ROY
Bachelor of Science (B.Sc.):
Institution : BGMEA University of Fashion & Technology
Department : Textile Engineering
Major : Yarn Manufacturing Engineering

3. What is PDCA ?
Background
Phases of PDCA
When to Use Plan–Do–Check–Act
Case Study
Benefits of PDCA
Content

4. 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

5. What is PDCA?
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)

6. Background
Walter Shewhart(1920)
Shewhart Learning and
Improvement cycle
W.Edwards Deming (1950)
Itis a combination of
management thinking with
statistical analysis
Japanese translation into
English became PDCA.

7. PDCA –Overview
Plan
Do
Check
No
Modify
parameters
Achieved
goal?
Yes
Act
Another problem
or improvement

8. Four Phases of PDCA
Plan a change aimed at improvement
Do – Carry out the change
Check/Study the results
Act - Adopt, adapt, or abandon

9. PLAN
Analyze current condition
Identify exactly what your problem is
Map the process
Establish the objectives

10. 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.

11. Check/Study
•Study the actual results (measured and
collected in "DO" above)
•Compare
•Against the expected results

12. Act
Take action based on what you learned in the study step
Two Possibilities
1.If the change did not work, go through thecycle again with a
different plan.
2. If you were successful then standardize

13. .
When to Use Plan–Do–Check–Act?
1
• As a model for continuous improvement.
2
• When starting a new improvement project.
3
• When developing a new or improved design of a process, product or service
4
• Exploring a range of possible new solution to problem

14. When to Use Plan–Do–Check–ACT?
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

15. 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.

16. Quality Management Methodology
Three Stages of Quality Management
• Assessment of quality management processes
• General quality data analysis
• The application PDCAcycle (to solve a specific problem that was
considered a priority in the previous step

17. 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).

18. In Quality Assessment Process we evaluate that we are
following the quality Processes or not like Quality Planning,
Quality Control and Quality Improvement
ByAnalyzing 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.
PDCAQuality Improvement Process used to solve the Quality
Problem
PDCA

19. 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.
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

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

21. Act
Act Phase
The last step of the PDCAcycle is based on the standardization of the
actions in which effectiveness was observed in the Check step

22. Benefits of PDCA
Effective and rapid method for implementing
continuous improvement
Minimizes Cost
Built-in Check.
Expandable
Standardized method
Fosters teamwork

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