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PROPRIETARY1APSTrainingModuleQF–PDCAAutoliv1June2006QF-TM-024-C1.0PROPRIETARYQF-TM-024-C1.0–PDCAPageof32QualityassuranceQualitymethodsSixSigmaStandardsPullsystemSafety&ErgonomyDon’tjudge,don’tblame!Flexibility&MotivationDisciplinetostandardsContinuousimprovementProcess&ResultQualityfirstProfitabilityCompetitivenessSatisfactionEmployeeinvolvementTeamwork5SMudaeliminationTPMJustintimeLeveling&CapacityLineconceptsContinuousflowTakttimeFrequentdeliveriesProcess&ResultsTeamWorkContinuousImprovementQualityMethodsPROPRIETARYQF-TM-024-C1.0–PDCAPageof32WhythistrainingDuringthistrainingyouwilllearn:•WhatisPDCA?•WhendoIpracticePDCA?•IsPDCAaversatiletool•WhenisthePDCAprocesscompletePROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCADefinedPlanDoCheckActPROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAis…AsimplebuteffectiveproblemsolvingmethodAcontinuousimprovementmethodAnd…MethodinwhichwedoworkshopsAnd…PROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAisatoolfor…1.ProblemSolving2.ContinuousImprovement3.WorkshopsPROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCASuccessMustbeusedconsistentlyEmphasisonDOINGPracticePDCA,andseetheeffectivenessPROPRIETARYQF-TM-024-C1.0–PDCAPageof32BasicPhilosophyofPDCAPlan:SetobjectivesandbuildanlogicalplanCheck:Study,analyzetheresultsDo:ExecuteplanTesttheplanAct:Control,LessonsLearned,standardize,preventrecurrencePROPRIETARYQF-TM-024-C1.0–PDCAPageof32PLANPROPRIETARYQF-TM-024-C1.0–PDCAPageof32Plan1.Graspcurrentcondition2.SetaSMARTGoal3.Gotothegembaandobserve!4.Identifyproblems5.Setexpectations6.WhyThisWorkshopPROPRIETARYQF-TM-024-C1.0–PDCAPageof32QuestionsforPlan•Whatdowewanttoaccomplish?•Howwillweknowit’sanimprovement?•keyindicators•before-after•Whatchangeswillgiveustheresultwearelookingfor?•Whatresourcesareneeded?PROPRIETARYQF-TM-024-C1.0–PDCAPageof32PlanTakethetimeupfronttoplan,andyouwillbesuccessful.Ifyoufailtoplan,youplantofail.PROPRIETARYQF-TM-024-C1.0–PDCAPageof32Bewareof…AnalysisParalysisPROPRIETARYQF-TM-024-C1.0–PDCAPageof32Mayhavesomesetbacks,butimprovementwillalwaysbegreaterovertimePDCACyclePlanningForPerfection(PFP)ImprovementTimePDCACyclevs.PFPPROPRIETARYQF-TM-024-C1.0–PDCAPageof32DO!PROPRIETARYQF-TM-024-C1.0–PDCAPageof32Do•ExecutePlan•ThisIsAnExperiment•Test•Measure•Actionregister•BeCarefulToCollectNecessaryDataPROPRIETARYQF-TM-024-C1.0–PDCAPageof32CHECKPROPRIETARYQF-TM-024-C1.0–PDCAPageof32Check•Follow–up•Studyresults•Howdidwedo•Keyindicators•Deepreflection•“Arewebetter?”•Resultsmayrequireyoutogobackto“Plan”PROPRIETARYQF-TM-024-C1.0–PDCAPageof32ACTPROPRIETARYQF-TM-024-C1.0–PDCAPageof32Act•Controlprocess/operation•Makedecision•Preventreoccurrence•Whereelsecanthisapply–lessonslearned•Before/Afteranalysis•Create/updatestandard•Whatisnext!PROPRIETARYQF-TM-024-C1.0–PDCAPageof32KeepinMind•Wecanrevise“Plan”•PDCAissimpleandflexible•PDCAisacycleActCheckDoPlanPROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAExampleTheProblem:Plasticpress-inhasbecomeverydifficultfortheoperatorstopushin.Recentlythesupplierchangedmaterialforacostreduction.PROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAExampleCheck:-Newpartarejustashardtopushin.-Welostourcostsaving.-Incurredachangecostfromsupplier.-DeepreflectionrevealsweweregoingthroughmotionofPDCAandnottherealintentPlan:HavecustomerswitchbacktooriginalformulaDO:Givethenewparts(oldformula)tocelltotry.Act:DoPDCAwithrealintentPROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCA–Cycle2Plan:-Determinephysicaldifferencefromthetwoformulas.-Investigateotherpossiblecauses(holediameter,etc).-Investigateenvironmentalcauses.DO:-Testphysicalpropertiesofthetwoparts-Checkholediameter-Observeatgemba-talktooperatorsPROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCA–Cycle2Act:Determineiftemperatureaffectspush-inforceCheck:-Physicalpropertiesverysimilar-HolediameterOK-Operatorrevealsthatproblemoccurredafterlinewasmoved-NoticedpartslocatedbycoolingventPROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCA–Cycle3Check:-Haveoperatorrunpartsambienttemperature.-Operatorhashappyfinger.Plan:TestpushforceatdifferenttemperatureDO:MeasureatambientandventtemperatureAct:Movepartsawayfromvent,andcreateblocksopartscannotbeplacedbackbyvent.PROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAExample–#2TheMedicalSchoolStudentopportunitiesPROPRIETARYQF-TM-024-C1.0–PDCAPageof32AnotherPDCAExampleImprovement:Isabelthinksthatshehasspenttoolittletimestudying.Shefeelsthatthebestwaytoimproveherstudyskillsisbyputtinginmorehours.Keyindicator:Takingoldexams.TheProblem:Isabelisafirst-yearmedicalstudentwhohasjusttakenherfirstsetofexaminationsandisveryunhappywiththeresults.PROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAExample–Cycle1Check:Noimprovementonexam–Tired–Lowconcentration-NofriendsPlan:Study30morehoursaweek,getupearlier,gotobedlater,takeoldexamatendofweekDO:Studiedonly15hours:FindmethodthatwillallowexerciseandsociallifePROPRIETARYQF-TM-024-C1.0–PDCAPageof32PDCAExample–Cycle2Check:Betterresultsonexam,stillneedsmorestudybutnotinterferewithexercise&socialPlan:Consultfriends,attendallclasses,rewritenotes,studytextbasedonprofessoremphas