The document discusses the PDCA (Plan-Do-Check-Act) cycle, which is a popular problem-solving and continuous improvement methodology. It describes the four steps of the cycle as Plan, Do, Check, Act. Each step is then further broken down into sub-steps or phases. For example, the Plan step involves selecting an improvement opportunity, analyzing the current situation, identifying root causes, and generating and choosing solutions. The document provides examples and explanations of how to implement each phase of the PDCA cycle for process improvement. It also lists some useful tools that can be used with the PDCA cycle and highlights benefits such as encouraging problem-solving, testing solutions before implementation, and bringing organizations closer to their goals through

1. PDCA Cycle | Plan
Do Check Act |
Implementation

2. PDCA CYCLE
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TUTORIAL

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.

5. Continuous Improvement Cycle
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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

7. Four Phases of PDCA Cycle
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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

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