PDCA Cycle

PDCA Cycle was originally developed by Walter Shewhart, and is often referred to as "the Shewhart Cycle". It was taken up and promoted very effectively from the 1950s by the famous Quality Management authority, W. Edwards Deming, and is consequently known by many as "the Deming Wheel". A strategy used to achieve breakthrough improvements in safety, quality, morale, delivery cost, and other critical business objectives.

The four steps in the cycle are exactly as stated.

First, PLAN carefully what is to be done. Next, carry out the plan (DO it). Third, CHECK the results-did the plan work as intended or were the results different? Finally, ACT on the results by identifying what worked as planned and what didn't.

There are seven phases of PDCA Cycle.

Phase 1: Identify the Opportunity

The objective of this phase is to identify and prioritize opportunities for improvement. Problem identification answers the question, "What are the problems?" The answer leads to those problems that have the greatest potential for improvement and have the greatest need for solution.

Problems can be identified using management tools such as Affinity Diagram, Brainstorming, Cause and Effect or Fishbone Diagram, and can be prioritized thru the aid of a Pareto Analysis.

Phase 2: Analyze the Current Process

The objective of this phase is to understand the process and how it is currently performed. Key activities are to define process boundaries, outputs and customers, inputs and suppliers, and process flow; determine levels of customer satisfaction and measurements needed; gather data; and identify root causes.

Phase 3: Develop the Optimal Solution(s)

This phase has the objective of establishing potential and feasible solutions and recommending the best solution to improve the process. Once all the information is available, the project team begins its search for possible solutions. More than one solution is frequently required to remedy a situation.

Phase 4: Implement Changes

Once the best solution is selected, it can be implemented. This phase has the objective of preparing the implementation plan, obtaining approval, and implementing the process improvements.

Phase 5: Study the Results

This phase has the objective of monitoring and evaluating the change by tracking and studying the effectiveness of the improvement efforts through data collection and review of progress. It is vital to institutionalize meaningful change and ensure ongoing measurement and evaluation efforts to achieve continuous improvement.

Phase 6: Standardize the Solution

Once the team is satisfied with the change, it must be institutionalized by positive control of the process, process certification, and operator certification. Positive control assures that important variables are kept under control. It specifies the what, who, where, and when of the process and is an updating of the monitoring activity.

Phase 7: Plan for the Future

This phase has the objective of achieving improved levels of process performance. Regardless of how successful initial improvement efforts are, the improvement process must continue. Continuous improvements mean not being satisfied with doing a good job or process but striving to improve that job or process. There is no such thing as BEST WAY. There will always be a BETTER WAY.

Source: Total Quality Management International Edition, Second Edition

Authors: Dale H. Besterfield
Carol Besterfield-Michna
Glen H. Besterfield
Mary Besterfield-Sacre