Transcript PDCA - A3 Report

A3 Training Session
Introduction….
• We all are involved in…
– Looking for ways to save resources
– Finding ways to improve quality
– Fixing problems
– Finding better ways to do things
• In each case, we also need to
communicate & share…
– Report to supervision
– Help others learn from our success and failures
How do we get better in our abilities to….
Make
Improvements &
Communicate ?
• Lets find a proven method…..
• Based on sound principles…..
• With a track record of success…..
The Scientific Method….
• Developed in the early 1600’s by Sir Francis
Bacon
• Widely used and adopted by the scientific
community from that time forward
• Modified and made popular in the mid 1900’s
by Walter Shewhart and Edward Deming,
becoming the “PDCA Cycle”.
These men are known as the Fathers of Statistical Quality Control and Quality Control
respectively
PDCA Cycle
• Plan
Understand the problem/situation, create plan
to see if assumptions are correct
• Do
Run test
• Check
Evaluate the results of the test
• Act
Respond to the results, act upon
what has been learned
The power in using this method comes from:
– Following the standard method, which
encourages accuracy and completeness
– Repeating the cycle, upon completion,
“once a hypothesis is confirmed (or
negated), executing the cycle again will
extend the knowledge further. Repeating
the PDCA cycle can bring us closer to the
goal, usually a perfect operation and
output”
Wikipedia
How are the Scientific Method and A3
Reporting related?
• The A3 Report is a “picture” of the
PDCA cycle
• And is a great tool to share the
progress and results of the efforts to
others
A3 Report
•A3 represents the size of the paper (11 X 17)
•Is meant to guide through the PDCA cycle
•Is not meant to require significant efforts to
document the “project”, do by hand at first
•Documents each of the PDCA steps, on a high
level
•Is meant to be very visual
•Is meant to contain data to support
understanding of the “problem” (plan) and
results of the “experiment” (Check)
What does an A3 Report look like?
What does an A3 Report look like?
Title: _________________________________________
COUNTERMEASURES (ACTION ITEMS)
BACKGROUND
• Make sure action items address the potential Root-Causes
• Identify who is responsible for the action item
• Be clear on exactly what is expected
• Clarify due dates for all actions
• Clarify implementation order and location clear
• May include Gantt Chart (Timeline)
• Write according to target audience
• Provide clear understanding of problem/issue
• Include historical data, dates, names that might provide insight
• List individuals participating in the event
• Use VISUAL information as much as possible
CURRENT CONDITIONS
• Depict an overview of the current process or system
• Highlight key features in the current state
• Identify what you know about the problem. What it is, is not?
• Use data, numbers to further explain the current situation
• Use visual methods of explanation when possible
GOAL/TARGET
EFFECT CONFIRMATION
• Set a clear goal or target state for the situation
• Be clear on the measure of performance
• Consider how to collect the data to evaluate effectiveness
• Use visual methods of explanation when possible
• Determine ways to confirm effect, by each root cause if possible
• Plan in advance for data to be collected
• Collect data, verify effectiveness of action items
• Use the same measures as called out in goal section
• Show data and how it confirmed, or not, action items
ROOT CAUSE ANALYSIS
FOLLOW UP ACTIONS
• Show the Root Cause identified
• Separate Symptoms and Opinions from cause and effect
• Show the tools used in Root Cause analysis (5 whys, Fishbone, etc.)
• Identify tests needed to build confidence in Root Cause analysis
• Summarize main findings of the Root Cause analysis, Visually if possible
• Standardize those countermeasures that had a positive effect
• Look for similar processes that may benefit from what was learned
• Re-address any Root Causes that remain a problem
• Plan next steps, may include next “cycle” of PDCA
Root Cause Analysis
• Often the most missed step
• Various tools to help get to the Root Cause
– 5 Whys – ask the question “why” at least five times,
until arriving at the root cause
• Example – The Car Won’t Start:
1.
2.
3.
4.
5.
6.
Why won’t the car start? Appears to not be getting fuel
Why is it not getting fuel? No fuel is getting to the fuel injection system
Why fuel not getting to the fuel injection system? Fuel is not coming from
the pump
Why is fuel not coming from the pump? The fuel is not getting to the pump
Why is fuel not getting to the pump? There is no fuel in the gas tank
Why is there no fuel in the gas tank? The kids don’t want to use their own $
to put fuel in the gas tank.
Root Cause Analysis
Ishikawa Diagram
A3 EXERCISE
Handwritten, group exercise
“POOR MPG ON KID’S CAR”
Root Cause Analysis
– Fishbone Diagram
MAN
METHOD
Environment
Always Late
Drive Like friends
Don’t Understand
Impatient
Don’t Understand
Poor Training
Not Trained Properly
Extreme Cold Weather
Poor Training
Poor Driving Habits
Not Warming Up Properly
Fast Starts and Stops
Poor Hearing
Don’t Understand
Poor Training
Poor Maintenance
Don’t Have $
Extreme Hot Weather
Radio Loud
Poor Training
Can’t Hear Engine
Don’t Understand
High Altitude
Poor MPG
Poor Fuel Economy
on Kids Car
Don’t know right oil
No Tester Don’t Know
Poor Training
Under Inflated Tires
No Owner’s Manual
Hard to check and fill
Poor Design
Wrong Oil
Improper Use of A/C
Improper Training
Using Wrong Gears
Too Much $ on Gas
Not Warming Up Properly
No Owner’s Manual
Improper Lubrication
No $
No Oil Change
No Follow Up
Lacks Time
Lacks Understanding
Lacks Patience
Wrong Fuel Octane
Poor Adjustments
Fuel Mix too Rich
Mech Lacks Knowledge
MACHINE
Poor Operator Training
No Owner’s Manual
Don’t Know Rec Octane
Lacks Time
Lacks Understanding
MATERIAL
Management
Lacks Patience
What’s the next step?
1.Find an opportunity for
improvement
2.Talk to supervisor, get OK to begin
work
3.GO FOR IT!
Oh, don’t forget to share your A3 with
others, & repeat the cycle