PDCA Plan Do Check Act

Outline
 What is PDCA ?
 Background
 Phases of PDCA
 When to Use Plan–Do–Check–Act
 Case Study
 Benefits of PDCA

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
[1].http://whatis.techtarget.com/definition/PDCA-plan-do-check-act

What is PDCA?[1]
 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)

Background
 Walter Shewhart (1920’s)
Shewhart Learning and
Improvement cycle [2]
 W. Edwards Deming (1950’s)
[2]
 It is a combination of
management thinking with
statistical analysis
 Japanese translation into
English became PDCA.
[3]https://www.isixsigma.com/dictionary/deming-cycle-pdca/
[2]https://www.ncbi.nlm.nih.gov/pmc/articles/PMC2464836/

PDCA – Overview
Plan
Do
Check
AchievedNo
Modify
parameters
goal?
Yes
Act
Another problem
or improvement

Four Phases of PDCA [5]
 Plan a change aimed at improvement
 Do – Carry out the change
 Check/Study the results
 Act - Adopt, adapt, or abandon
[5]www.yourarticlelibrary.com/business/continuous-business-process...4-phases/21128/

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

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.

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

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

 As a model for continuous improvement.
 When starting a new improvement project.
 When developing a new or improved design of a process,
product or service.
 Exploring a range of possible new solutions to problems
When to Use Plan–Do–Check–Act?[7]
[7]http://asq.org/learn-about-quality/project-planning-tools/overview/pdca-cycle.html

 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.
When to Use Plan–Do–Check–
Act?
[7]http://asq.org/learn-about-quality/project-planning-tools/overview/pdca-cycle.html

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.

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

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).

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

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.
• The thickness of the component is outside the specification limits of
0.40 ± 0.05 mm;

 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

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

Act
 Act Phase
 The last step of the PDCA cycle is based on the standardization of the
actions in which effectiveness was observed in the Check step.
 Result

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

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

References
[3]https://www.isixsigma.com/dictionary/deming-cycle-pdca/
[2]https://www.ncbi.nlm.nih.gov/pmc/articles/PMC2464836/
[4]www.change-management-consultant.com/deming-cycle.html
[5]www.yourarticlelibrary.com/business/continuous-business-
process...4-phases/21128/
[6]www.brighthubpm.com › Methods and Ideologies
[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.
[7]http://asq.org/learn-about-quality/project-planning-
tools/overview/pdca-cycle.html

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