PLAN DO CHECK ACT (PDCA) “The Scientific Method to Improvement”

Introduction and Overview

Learning Objectives

• Name 3 people who played a role in the origin of PDCA

• Describe 2 requirements of the PDCA Method to problem solving

• Describe each step of the acronym PDCA

• Name a Leader in Quality who supported and promoted PDCA scientific process

• Describe Where and When you should apply PDCA Method

• Describe How to apply PDCA Method to daily problems

Origin of Plan Do Check Act (PDCA) also known as the Shewhart Cycle.

Sir Francis Bacon 1620 Created the Baconian Method, the “Scientific Method”

Scientific Method = "hypothesis/theory" - "experiment" - "evaluation" or plan, do, & check

He created the foundation for PDCA

Edwards Deming 1924 Deming was Walter Shewhart’s boss at Western Electric / Bell Laboratories Made PDCA popular through his work as a Leader in Quality

Deming preferred Plan Do Study Act (PDSA) while teaching quality in Japan in the 1950’s

Walter Shewhart 1924

Was an American physicist, engineer, and statistician.

Sometimes known as the Father of Statistical Quality control.

Created PDCA cycle while working at Western Electric / Bell Laboratories

PDCA: is a Scientific Method to solving problems

requires facts, measurement, objective analysis and critical thinking surrounding the problem

requires data and numerical evidence of the problem

is designed to be applied over and over again, not just one time

– referred to as “Closed Loop Thinking”

naturally increases knowledge of the individual(s) evaluating the causes of a problem

What is the Plan Do Check Act (PDCA) Method?

Standards, Process Improvement and the PDCA Method Constant

Consistent &

ContinuousChange for the Better

The Current Standard serves as “The Chock” to PREVENT BACKSLIDING”

“CHAOS” WILL TAKE OVER > STANDARDS WILL BACKSLIDE

If we DON’T continuously improve wewill experience a NATURALLY occurring Re-action!

CONTINUOUS

IMPROVEMENT

A

PROCESS

What are the steps of PDCA?

Plan

“When faced with a problem, we naturally begin to ask questions”

• What is the problem?

• Why is the problem occurring?

• How does the problem start?

• What are the causes of the problem?

• Can we measure the problem?

Plan =

Identify, Define, Measure, create a baseline, set a goal/targetCreate a “test/trial” and corrective actions to improve the problem using a Scientific Method to obtain a different result

“Let’s go test our corrective action to the problem”

Do

• Run a Trial and measure the results

• Test what we believe is the best / workable approach

• Use the data and facts from Plan step as Baseline

Do =

Implement the Plan Perform the Test/Trial you created Monitor the change during implementation

“Were the results what we expected?”

Check

• Measure to Validate and Verify what changed

• Compare results of test to baseline data

• If a change occurred, ask Why did it change?

• Did the problem: get better, get worse, or stay the same?

Check =

Reflect and compare baseline data to new data obtained from testDetermine if an improvement occurred

“Implement the New and Improved Standard”

Act

• Stabilize new Standard

• Train others to new method

• Update process improvement metrics where and when required

• Share new standard

• Re-Apply the PDCA Method over again.

Act =

If No improvement occurred Go Back to Plan

If a change for the better occurred then Stabilize and Standardize the new method, teach others of new method and start the PDCA cycle again.

PDCA Summary

Learning Objectives

• Name 3 people who played a role in the origin of PDCA

• Describe 2 requirements of the PDCA Method to problem solving

• Describe each step of the acronym PDCA

• Name a Leader in Quality who supported and promoted PDCA scientific process

• Describe Where and When you should apply PDCA Method

• Describe How to apply PDCA Method to daily problems

Exhibit A: Plan Do Check Act / Standardize Do Check Act

Exhibit B: Repeating PDCA