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Kaizen PDCA _ Plan Do Check Act _

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					Training Pack




Kaizen
PDCA ( Plan / Do / Check / Act )
                        Introductions

• Name

• Department

• Current knowledge of Plan Do Check Act
                    Aims & Objectives

Target Audience : All!

Purpose of Module :

To train the delegates in the Continuous Improvement Cycle

Aims & Objectives :

           • Understand the origins of Plan/Do/Check/Act (PDCA)

           • To define the 12 step PDCA approach

           • Understand when to apply PDCA
                              Definition

Plan Do Check Act (PDCA) is a framework that provides a
methodical approach to problem solving and continuous
improvement.


It’s not just a 12 step cycle, it’s a way of thinking!




                                                           Act
                                                                 Plan
                                                         Check
                                                                 Do
                                      Standard Ops.          CONTINUOUS
                                                            IMPROVEMENT
                           Why use PDCA?
 Human nature                                   vs.   Process


  Jump straight to solution mode                             Allow time to plan




                   Fight the fires every time             A structured approach
                                                          to defining the problem




No common understanding
    of the real problem                                   Involve the right people




                   No measure if the solution            Test and monitor solutions
                      is a real success
                                                          to ensure goals are met
                       The PDCA Cycle


            12. Continuous      1. Select Project          2. Explain
             Improvement                                    Reason



    11. Monitor
                                                                  3. Set Goals
     Solution
                             ACT               PLAN


10. Implement                                                           4. Prepare
                                       Continuous
   Solution                           Improvement                       Action Plan
                                         Cycle


                             CHECK                  DO
    9. Ensure
                                                                 5. Gather the
    Goals are
                                                                     data
    satisfied


                 8. Test                                 6. Analyse the
                Solutions                                     facts
                                     7. Develop
                                     Solutions
                                                                                                                                                              1. Select Project
   When selecting a project think about how you can identify that an area requires
   improvement. What inputs help you recognise if an area is not conforming to the
   required standard?
4 Hour FIT - Day 1                                                            Brainstorming - What can we

Team Name:
                                                                                       improve??                                                                                      Health & Safety
Team Members:                               Low Cost
                                      Can be Done This Week                                                                                                      5                                                              0.07
                                                                                    Low Cost
                                                                             Will Take Longer Than                                                                                                                              0.06
                                                                                     a Week                                                                      4
                                                                                                                                 High Cost                                                                                      0.05
                                                                                                                                                                                                                                       Others:-
Area to be targeted:
                                                                                                                          Long Term Improvements                 3                                                              0.04
Issues Encountered:
                                                                                                                                                                 2                                                              0.03
                                                  Priority Table - Prioritise ideas according to the ease, benefit & cost of
                                                                                                                                                                                                                                0.02
4 Hour FIT - Day 2                                                                                                                                               1
                                                                                              implementation
Improvement to be tackled:                                                                                                                                                                                                      0.01
Current State Photos:
                                                      Improvement Idea                            Ease       Cost Impact Total           Rank Who??
                                                                                                                                                                 0
                                                                                                                                                                     Oct    Dec    Feb     Apr     Jun     Aug    Oct     Dec
                                                                                                                                                                                                                                0      FMEA’s
Priority Table Scoring:
1 = Hard to install/ High Cost/ Low
                                                                                                                                                                                  Work Related Accidents     Reportable Accidents
Impact
5 = Easy to install/No Cost/High
Impact
                                                                                                                                                                                  Sickness Rate %
4 Hour FIT - Day 3
      Gap Analysis
     Current           Future
                                      Countermeasure
                                        How can we solve it?                  o n rm a u
                                                                             C u te e s re
                                                                                                                  Action Plan

                                                                                                                W o S p o W e C m e ts
                                                                                                                 h ? u p rt h n o mn                                                                                                   Risk Assessments
                                                                                                                                                                     KPI’s

4 Hour FIT - Day 4

                                                                                                                                                                                                                                       Customer Feedback
                                                                                                                                                        No
                                                                                                    Wh at actio ns are      REC OV ERY       Su ccessfu l?
                                                                                        No             re quire d?            PLAN
Evaluation & Review                                                          Imp lem e nta tion                                                        Y es
                                                                               Su cce ssful?
Was the improvement
implemented?                                                                            Yes
                                                                                                      Ho w can th e
                                                                                                       ch ange be
                                                                                                                              PLAN TO
                                                                                                                              SUSTA IN
                                                                                                       sustain ed?


                                                                                     Action                   Who?       Support   When By        Comments
After Photo:




                                                                                                                                                                                                                                       (Int/Ext)
                                                               New Actions




Team Achievements:




Focused Improvement
Teams (FIT)                                                                                                                                                                IPT meetings
                          2. Explain Reason

Achieve this by producing an agreed, clear problem statement, that uses facts,
and does not mention any countermeasures.




Example
After Process X has finished, the operator on the machine is expected to inspect the
product, and then certify in SAP that the process has been successfully completed.
However the Team Leader on Process Y complains that half of the time, products arrive
without having the correct certifications, which stops his team from doing their job. He
has to spend, on average, 2 hours sorting the problem.
He reckons that this has got worse since they changed the version of SAP used 6
months ago (he and his team still hasn’t been trained), and they have taken SAP access
away some operators. Production has also risen recently, putting strain on resource.
                  2. Explain Reason

1. Everyone needs to be trained on SAP
2. More SAP certification access is required
3. More people are required on Process X

Pre-empts countermeasures without understanding
the problem – based on opinions not facts


“In the last 6 months, 50% of products arriving at
Process Y have arrived without the proper SAP
certifications, causing on average 2 hours delay per
occurrence”.

States the facts, giving frequency, timescale, and
impact.
                       3. Set Goals
Using the previous example of Process X and Y:


 To identify and implement the requirements that will
 ensure that 75% of products arriving at Process Y
 have completed certifications within 6 months, rising
 to 100% by the end of this year.




S.M.A.R.T.!!!
                           4. Action Plan

Specific actions should be highlighted for completion. The key here is that
plans should be time-bound and bought-off by the relevant owner.


Why are we undertaking the project?


        What are we going to do? What data is required?


               Who is responsible for each task? Who should be involved?

                      How must it be accomplished? How do we review?


                            Where can we find relevant data and facts?


                                      When must a task be complete?
                                                 ...do we need to give feedback?
                        5. Gather the Data

Gathering data enables us to understand the current situation to
discover the extent of a problem. Data provides the information required
to analyse a problem.


Data can be collected in a number of ways and forms, depending what you problem are
trying to define:


Interviewing
                            Visit the shopfloor – “Go and See”
Machine Histories
                            Risk Assessments
Customer Returns Data
                            Scatter Diagrams, Checksheets - 7 Quality Tools
                   6. Analysing the Facts

It is important to use the correct tools to define the problem. Only then can
relevant data be collected in an appropriate form to allow solutions to be
generated and their effectiveness reviewed.


Checksheets
Histograms                                      Data Collection
Scatter Diagrams
Control Charts                                  Data Collection & Analysis
Flow Charts

Cause and Effect Analysis
                                                Analysis Techniques
Pareto Analysis
                          Tool Deployment

              Situation                              Tool
1.   Tracking OEE                       Scatter Diagram
2.   Most frequent causes of            Flowchart
     Downtime
                                        Histogram
3.   Location of concessions on a
                                        Control Chart
     Panel
                                        Checksheet
4.   Identifying possible reasons for
     poor delivery                      Pareto Analysis
5.   Understanding process for          Cause and Effect Analysis
     modifying tooling
6.   Making sense of accident data
                Planning for Data Collection

                What question do we need to answer?

What data analysis tools are we going to use and how to communicate the results?

              Who in the process can give us the data?


        What type of data do we need to answer the question?

         Where in the process can we get the data we need?

 How can we collect this data from the individuals with minimum effort and error?

                   When is the data to be provided?

                How much will it cost to collect the data?

        What additional information do we need for future analysis?
                        Develop Solutions

Develop countermeasures by brainstorming all the potential root causes to the
problem.



                                                                   Ask Why?
  Brainstorm             Group               Prioritise
                                                                   5 TIMES!




Remember:- the customer protection is a temporary fix that solves the
problem today, the countermeasure is the permanent solution that
prevents the problem re-appearing.
                         7. Develop Solutions

Tips for Brainstorming:
Have a clear and understood objective
• Requires group participation
• Quantity not Quality
• No criticism is allowed – no idea is a bad idea
• Do not work an idea during the session
• One person to scribe the ideas onto a board or flipchart
• Piggy back off other people’s ideas
• Think “outside of the box”
• Run a session for around 15 minutes
• Have a break before analysing the ideas
                             5 Why’s Example



             1                              2                           3
Q : WHY has machine stopped ? Q : WHY overload trip ? Q : WHY Insufficient oil ?
    A : Overload tripped out ! A : Insufficient oil on shaft ! A : Oil pump inefficient !


                                    Root-cause

                      4
          Q : WHY is pump not efficient ?
                                                             5
                                                  Q : WHY is this shaft worn ?
            A : Pump drive shaft worn !          A : Oil filter blocked with swarf !
                                                                     8. Test Solutions

    Once the countermeasures have been identified and prioritised, they
    have to be tested to assess the effectiveness.

    Think about how the success of potential solutions could be measured:

    Is a trial required?                                          Who needs to know?
                                                                  How many communications sessions are needed?
                                                                  How will the issues from the trial be captured?




          Maybe more more data need to be collected?
                    Health & Safety
5                                                             0.07
                                                              0.06
                                                                       Does this data coincide with that collected
4
                                                              0.05
3                                                             0.04     to define the problem?
2                                                             0.03
                                                              0.02
1
                                                              0.01     Is it a KPI, one of the 7 Quality Tools?
0                                                             0
    Oct   Dec    Feb     Apr     Jun     Aug    Oct     Dec
                                                                       If so, will comparisons be possible to assess impact?
                Work Related Accidents     Reportable Accidents
                Sickness Rate %
               9. Ensure Goals are Satisfied

Assess the success of the tested countermeasure by comparison with
the goals set in Step 3


• If the goals have been met, the countermeasure can be implemented.




• If the goals have not been met, then the following should be considered:
                                                                      12. Continuous           1. Select Project    2. Explain
                                                                       Improvement                                   Reason

Develop the existing countermeasure
                                                          11. Monitor
                                                                                                                             3. Set Goals
                                                           Solution
Can additional countermeasures be developed?                                           ACT                 PLAN



                                                      10. Implement                                                                 4. Prepare
How appropriate are the goals?                           Solution
                                                                                                   Continuous
                                                                                                  Improvement
                                                                                                     Cycle
                                                                                                                                    Action Plan

                                                                                       CHECK                  DO

                                                        9. Ensure Goals                                                      5. Gather the
                                                          are satisfied                                                          data

Re-evaluating the goals means a return to Step 3!!
                                                                  8. Test Solutions                                6. Analyse the
                                                                                                                       facts
                                                                                                 7. Develop
                                                                                                  Solutions
             10. Implement Coutermeasures

Ensure everything is done to make a successful countermeasure become the
new standard


• If it meets the objective set, then it must become the standard way of working.


• All relevant people informed,


• Training needs to be identified and addressed


• Necessary documentation updated


• Use Standard Operating Sheets to document the new standard
              11. Monitor Countermeasures

Continuously gather the data and analyse the facts to monitor the
effectiveness of implemented countermeasures


• Repeat Steps 5 & 6 of the PDCA cycle to establish the before and after
situation.




• Individuals involved need constructive feedback after implementing
countermeasures to help maintain continuous improvement.



                  Celebrate success!!!
               12. Continuous Improvement

By definition the cycle of improving and ever raising the standards never
stops!




• Ongoing process control can be used to ensure the performance of the
countermeasures consistently meet the objectives set




• Improvement is infinite!
                                                          Act
                                                                Plan
                                                       Check
                                                                Do
                                       Standard Ops.        CONTINUOUS
                                                           IMPROVEMENT
                    Aims & Objectives
Target Audience : All!

Purpose of Module :

To train the delegates in the Continuous Improvement Cycle

Aims & Objectives :

           • Understand the origins of Plan/Do/Check/Act (PDCA)

           • To define the 12 step PDCA approach

           • Understand when to apply PDCA

           ………..did we succeed?

				
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