Structured Approach to Problem Solving – PDCA & DMAIC

www.optimumfx.com

Intent of Session

This section is designed to:

• Introduce two simple methodologies for problem-solving projects

• Demonstrate how the tools and techniques fit into the phases of the methodologies

Why use structured approach?

• It is in our nature to see patterns and jump to conclusions (MOW - generalise)

Typical result

Same problem reoccurs

• By adhering to a structured process, we reduce the assumptions and avoid jumping to damaging conclusions

PDCA Cycle

Recognise an opportunity and Plan a change:

Define problemEstablish objectivesFocus on desired outcomeIdentify solutions

Test the changes on small scale. - minimise disruption and limit exposure

Check whether results are achieving desired outcome.Identify new problems as they arise

Implement on larger scale if successful.

Make part of routine.

Begin the cycle again.

If didn’t work, skip Act and go back to Plan to come up with new ideas.

PLAN

DOCHECK (study)

ACT

P

DC

A

1

23

4

PDCA Cycle – Stage tools

Plan for changes to bring about improvement:

BrainstormingFlowchartingPareto analysisSolution/Fault treeCause & Effect diagrams

Do changes on a small scale first:

Project Management skillsSmall-group leadershipConflict resolutionOn-job training

Check to see if changes are working:

Check sheetsKPIsControl charts

Act to get the greatest benefit from the changes:

StandardisationTraining

PLAN

DOCHECK (study)

ACT

P

DC

A

When to use Plan-Do-Check-Act

• As a model for continuous improvement.

• When starting a new improvement project.

• When developing a new or improved design of a process, product or service.

• When defining a repetitive work process.

• When planning data collection and analysis in order to verify and prioritize problems or root causes.

When implementing any change.

Example PDCA

– PLAN create meeting TOR

– DO test the TOR in a selected meeting

– CHECK analyse effect of using TOR

– ACT roll-out TOR to other meetings• return to Plan for continuous improvement of TOR

• Effective Meeting TORs

DMAIC MethodologySix Sigma methodology built on PDCAStage Description Example Tools

Define Define the problem and project elements: goals, form the team, set improvement target

Project Charter, Loss Analysis (OEE & Six Loss), Stakeholder Analysis/SIPOC, Process mapping

Measure Determine method of measurement and gather current baseline data

Value Stream Mapping, Check sheets, LineView Data, FMEA, Pareto charts

Analyse Analyse the data to identify root cause(s)

5 Whys, Fishbone, Cause & Effects matrix, Scatter plots, Hypothesis testing

Improve Generate improvement ideas to address root cause(s) & implement

Initiative Priorisation (Bubble Chart), Brainstorming, Ease & Effect

Control Confirm goals reached and implement actions to measure and sustain

One-Point Lessons, Control charts, SIC reviews, Milestone Planning

Large no. inputs

Vital Few

Impact of structured approach to problem-solving

• Step by step project methodology ensures fact-based decisions, rather than conjecture

• Simple tools & techniques to apply at each step

• Building in a control element provides for sustaining improvement and enabling on-going measurement