PDC
A
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TABLE OF
01. What is PDCA Cycle?
02. History of PDCA Cycle
CONTENTS
03. When to Use PDCA
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Method?
04. Steps in PDCA Cycle
05. Benefit of PDCA Concept
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WHAT IS PDCA
The PDCA cycle is a project
management tool that businesses
can use to implement incremental
change. PDCA stands for Plan, Do,
Check, and Act.
CYCLE
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HISTORY OF PDCA
• Introduce by Walter Shewhart build the foundation of
PDCA concept
• At first, he developed a 3-step repeating cycle for
process improvement also known as "the Shewhart
cycle". (Specify-Produce-Inspect) 4
• In 1950s William Deming expanded the concept into a
learning and improvement cycle known now as PDCA
cycle and introduced the concept in Japan
• His purpose was to use PDCA with a Continuous
se
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WHEN
TO USE
PDCA 5
METHO
D 5
4 STEPS IN PDCA is the foundation of
continuous improvement or
kaizen.
PDCA CYCLE • Leaders set target (Plan) against
stable baseline of performance.
PDCA
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• Teams implement improvement
(Do) to achieve the target.
• Then they measure (Check) the
change to evaluate performance
against the target.
• If the team has achieved a
measurable gain, it standardizes
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STEP 1 - PLAN
• In the planning phase, our focus on identifying current condition and opportunities for
improvement and proposing solutions to tackle these issues.
• This involves creating hypotheses about the underlying problems, benchmarking
current performance, and setting a target to improve on this performance.
Key steps in the planning phase include:
Defining problem→ Setting objectives→ Analyzing data→
A common challenge duringDeveloping
this phase plan
is ensuring that the proposed
changes align with the organization's overall business objectives.
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Before you move to the next stage, you need to be sure that you answered
some basic concerns:
• What is the core problem we need to solve?
• What resources do we need?
• What resources do we have?
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• What is the best solution for fixing the problem with the available resources?
STEP 2 - DO
• This stage is all about execution and change implementation.
• It involves three key steps: training team members to adopt the
change and bridge any skills gaps, implementing the proposed changes,
and documenting the process for future reference.
Key steps in the planning phase include:
Implementing solution → Monitoring closely→ Documenting
everything
Major challenge during this phase is ensuring that the team is
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adequately prepared and that the implementation goes smoothly.
With proper training and documentation, the process can avoid
major setbacks.
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STEP 3 -
• Check phase is essential for evaluating the success of your efforts
First, you analyze the results of your pilot test, comparing them
against the criteria established in the planning stage to determine if
CHECK
the changes were successful.
• This involves a comprehensive review to identify both successes
and opportunities for improvement (usually happen more than one
Key steps
time per project) in the planning phase include:
Evaluating results → Soliciting feedback → Identifying
discrepancies 9
A challenge here can be accurately measuring the outcomes and
determining what worked and what didn't. This can be tricky if the
criteria for success are not clearly defined in the beginning.
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STEP 4 - ACT
• The final step in the PDCA cycle is taking corrective action and adjusting to
implement the improvement project on a larger scale. This phase solidifies the
changes made and sets the stage for the future.
• After the final stage, start the process again. It doesn't matter if your change
led to improvements, as processes can constantly be improved.
• The PDCA should be utilized continuously to optimize and streamline processes
to maximize efficiency and production.
Key steps in the planning phase include:
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Making adjustments → Standardizing successful practices → Setting the stage for
continuous improvement
One challenge in this phase is ensuring that the changes are
effectively integrated into the organization without causing
disruptions, as scaling up can bring new obstacles that weren't
apparent during the pilot phase.
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Sustain &
STEPS IN
Share the
Standards
PDCA CYCLE
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Improvement activity must not only
continue when problem occur. But, need
to be continuously done to ensure good 11
BENEFIT OF
PDCA
CONCEPT
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T ECH NIQU E T O USE
WIT H PDCA CYCLE
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Others technique also can be utilized for PDCA
cycle mainly on QC 7 basic & new tools
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TECH NIQU E T O USE
S M A RT O B J E C
-> What will you achieve? T I V E S
EXAMPLE:
What will you do?
WIT H PDCA CYCLE
-> What data will you use to
decide whether you meet the
To reduce black dot in blade during injection
process by 50% in 6 months.
goal? To reduce lot out during incoming part
-> Are you sure you can do this? inspection by 10% in FY2024.
Do you have right skills and
resources? Use 5W 1H question during planning
stage to prepare & develop plan
-> Does the goal align with those
of your team or organization? How
will the result matter?
-> What is the deadline for
accomplishing the goal?
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TECH NIQU E T O USE
B RBrainstorming
A I N Stechnique
T R OusedMtoIcombine
N Glarge number of ideas from a group of
team members using its collective thinking power.
WIT H PDCA CYCLE
• It's a group activity with creative & high level energy member
• Should involve people that affected with the problem/ improvement action and
people with expertise. This to ensure ideas are in different perspective by
expanding view of issue and improvement.
Effective brainstorming session
1. Initiate rotation so that every member have equal chance to contribute
2. Pay attention to other's thought and opinion
3. Build on current thought & ideas
4. Stay concentrated on the subject and do not divert off topic
5. Do not give negative remarks
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TECH NIQU E T O USE
A UCause
S E& Effect
& Diagram
E F used
F EtoC TtheD
relate I AtoG
causes R A and
its effects Malso used in
brainstorming session
WIT H PDCA CYCLE
• Use when we want to zoom into specific causes of problems
• Use when we want to have broad thinking about possible causes
• Usually categorized possible cause based on Man, Machine, Method, Material,
Environment
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TECH NIQU E T O USE
MMatrix
AT R I
DiagramXhelpD I A G
to analyze R A
& evaluateMrelationship between 2 or more sets of data.
It is a method by which the Team can identify the priorities of a large list of Ideas/actions
or Causes.
WIT H PDCA CYCLE
When to use??
• When comparing 2 list to understand the many-to-many relationship
• When determining the strength of relationship
• When the second list is generated as a result of first lit (Ex: customer requirement vs
design specification)
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TECH NIQU E T O USE
5 W H Y ’ S A N A LY S I S
5 Why's Analysis is a simple way of finding out if the team has reached the ROOT CAUSE
of a problem.
WIT H PDCA CYCLE
• A structured approach in which you repeatedly ask WHY? to understand the
underlying causes of the issue, AND to generate an effective corrective action to
mitigate the incident, and prevent future occurrences.
• Is used to identify and/or to document the cause/effect relationships associated with a
problem/error and its root cause
• based on "hands on" observation/investigation (not just opinion)
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TECH NIQU E T O USE
. CHECKSHEET
A check sheet is a specially designed sheet used to collect data in real time and at the actual
location where the data belongs
• Limited data analysis can be done using check sheet, but it is powerful tools to summarize data into quality scorecard for
further analysis
WHEN TO USE??
WIT H PDCA CYCLE
• When we want to identify the frequency or pattern of problems, defects, defects location,
defects cause, etc
• When we want to collect data at production area
• When same person can repeat collecting data or at the same location • When collection
data occur at any step of project
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TECH NIQU E T O USE
7 . Matrix
M AT R I X
Data Analysis D
DiagramATA A
used to analyzeNtwoA LY
sets S I
of factors S
in a matrix form & get
numerical output. The data analyzed on options and factors that will reflect the list of options
(able to prioritize the action need to be taken)
WIT H PDCA CYCLE
WHEN TO USE??
• When prioritizing complex issue where there are multiple criteria for deciding importance
• •When to help select items to be implemented for larger list
D I AG RA M
• When want to gain agreement on priorities and key issues
Type of
Appearance
Long Battery
Function Reliability Price
Total
Mobile Life Scores
A 3 1 3 5 1 13
B 5 2 4 3 2 16
C 3 4 3 2 2 14
D 4 4 4 4 3 19
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TECH NIQU E T O USE
. FA U LT T R E E A N A LY S I S ( S M K
List of all Judgement
related parts Target date
Defect WIT H PDCA CYCLE
F O R M AT )
Testing List all the Countermeasure
List of all method to Action to Person in evaluation action if
factors that evaluate the evaluate the charge result judgement is NG.
potential to factor method.
cause the
defect
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EXAMPLE OF PDCA
CH ART- 1
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EXAMPLE OF PDCA
CH ART- 2A
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EXAMPLE OF PDCA
CH ART- 2B
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THANK
YOU!
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