The document outlines the Plan-Do-Check-Act (PDCA) model for continuous improvement. It describes how Walter Shewhart and W. Edwards Deming developed the model in the 1920s-1950s. The PDCA model involves planning an action, doing it, checking the results, and acting on what was learned. Examples are provided of how PDCA could be applied to new product development by planning a prototype, testing it, analyzing customer feedback, and implementing improvements. Tools for each phase and ways to apply PDCA in different areas like manufacturing, facilities, and maintenance are also discussed.

1. PLAN-DO-CHECK-ACT
JANUARY 2020

2. ◉ Walter Shewhart (1920’s) – Shewhart Learning and
Improvement Cycle
◉ W. Edwards Deming (1950’s) – It is a combination of
management thinking with statistical analysis
Background
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3. ◉ PDCA stands for Plan-Do-Check-Act
◉ Iterative four-stage model for continuous improvement
◉ It teaches organizations to:
PLAN an action
DO it
CHECK it
ACT on it
What is PDCA?
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4. PDCA Overview
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5. PLAN1
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A change aimed at improvement

6. ◉ Analyze current condition
◉ Identify exactly what your problem is
◉ Map the process
◉ Establish objectives
How do you plan?
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7. DO2
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Carry out the change

8. ◉ 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
How do you do it?
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9. CHECK3
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Study the results

10. ◉ Study the actual results (measured and collected in “do”
step)
◉ Compare against the expected results
How do you check?
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11. ACT4
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Adopt, adapt, or abandon

12. ◉ 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.
How do you act?
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13. Example:
Plan
Plan for the new product
development & production
process
Do
Create a prototype, test it,
& collect data from the
customer
Check
Analyze the collected data
to measure customer
satisfaction
Act
Fully implement the new
design/act on collected
feedback
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When a design team is planning for a new product development

14. Useful tools to use
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PHASE USEFUL TOOLS
PLAN Gap analysis, fault tree analysis, waste analysis,
brainstorming, process mapping, etc.
DO Gantt charts, on-the-job training, conflict resolution,
data collection methods, sampling, control charts, etc.
CHECK Graphical analysis, cause and effect analysis, statistics.
Pareto analysis, group decision-making technique, etc.
ACT Gantt charts, check sheets, control charting, control
planning, standard work, conflict resolution, etc.

15. How do you apply PDCA?
MANUFACTURING
Labor effectiveness
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FACILITIES
Uptime
ENGINEERING
Yield
CSIP
Internal Audit
QA&R
Inspection escapee
HR & Training
Certification
FINANCE
Accuracy of financial
statements
MAINTENANCE
Machine uptime

16. “
Insanity is doing the same thing
over and over again and
expecting different results.
- Albert Einstein

17. Any questions ?
Thanks!
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