The PDCA cycle (Plan-Do-Check-Adjust) is broken down into 7 steps.
Problem Statement
The Problem Statement is a
clear, concise and measurable description of waste, rework or deviation
from a standard (the norm). It should explain WHO is experiencing the
problem, WHEN they experienced the problem, and WHERE they experienced
the problem. The description must be measurable, and should refer to the
standard.
Goal Statement
The Goal Statement is the clear, concise, measurable and attainable objective. It must include a precise target date to accomplish the goal. The Goal Statement must mirror the problem statement.
Point of Cause
Think Cause and Effect. If the problem is
waste or the deviation from standard, then the point of cause is the
physical time and/or location the deviation is occurring. Apply the Because Equation to the problem to help define the Point of Cause (The problem occurs BECAUSE of the point of cause).
Root Causes
The root cause is the underlying reason –
often hidden or obscure – that is creating the problem. If the PDCA does
not identify and eliminate the true root cause (or causes, there could
be several of them) then the problem will most likely come back. You get
to root causes through 5-Why Analysis and other PDCA tools.
Counter Measures
Counter measures — the “do” phase of the
PDCA — are the actions the PDCA group will take to eliminate the root
causes, and ultimately prevent the problem from recurring. These actions
are specific activities that have a clear function, a beginning and an
end. Each counter measure must tie back to a root cause, and each
counter measure must support achieving the goal statement. A counter
measure must have a begin date and a target date (or expected date to
complete). One member of the PDCA group is responsible for ensuring the
counter measure is implemented by the target date; that group member
may only assist in doing the actual work or many not even be involved in
the actual work, but he or she is ultimately responsible to ensure that
it happens.
Follow Up
This is the “Check and Adjust” phase of
the PDCA. When the group first plans the counter measures to be taken,
they should schedule a time to return to check on their success. This
can be a week into the future, a month, six months, a year – depending
on the target date set in the goal statement. If the counter measures
were successful, standardize. If the problem still exists – which
happens – then adjust. That may mean simply modifying the counter
measure or stepping back and reviewing the Point of Cause and Root
Causes.
Follow-up is often the most ignored step in a PDCA cycle, and is arguably the most critical.
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