What is the PDCA cycle in TQM?

What is the PDCA model of continuous improvement?

What are the four steps in the PDCA cycle?

Plan – A change aimed at improvement Do – Carry out the change Check – Study the results Act – Adopt, Adapt, or Abandon

How to Implement the PDCA Cycle? Example:

Implementation of Plan Phase:

01. Select Improvement Opportunity

02. Analyze Current Situation

03. Identify Root Causes

04. Generate and Choose_Solution





[1] Select Improvement Opportunity:

[2] Analyze Current Situation:

[3] Identify Root Causes:

[4] Generate and Choose Solutions:

Implementation of Do Phase:

[5] Map Out and Implement a Trial Run:

Implementation of Check Phase:

06. Analyze the Results

07. Draw Conclusions





[6] Analyze the Results:

[7] Draw Conclusions:

Implementation of Act Phase:

08. Adopt, Adapt, or Abandon the Intervention

09. Monitor; Hold the gains

[8] Adopt, Adapt, or Abandon the Intervention:

[9] Monitor; Hold the gains:

Useful Tools for PDCA Cycle:

What are the benefits of the PDCA cycle?

→ 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.→ PDCA is widely recognized as the basis of continually improving the, 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,, A3 thinking methodology, and→ 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.for (1) What is the problem? (2) What is problem-solving? (3) Various Problem Solving Methods (4) Types of Solution.➝ There are four sub-phases are available in the planning phase which is explained below in sequence.➝ 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➝ 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➝ This is a very very important step➝ Utilize the(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➝ 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➝ 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.➝ The check phase has two sub-phases which are mentioned below.➝ 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.➝ 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➝ The last phase is the act phase and it has two sub-phases as mentioned below.➝ 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.➝ 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➝ There are several useful tools of the PDCA Cycle is mentioned in the below picture.➝ 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 implementand 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➝ It also Helps to reach towards a more integrated system.