Archive for November, 2011

Lean & PDCA (Part 1)

Sunday, November 27th, 2011

Lean initiatives can be implemented in a series of Plan-Do-Check-Act (PDCA) cycles. In addition to the value stream map metrics, is important to keep a set of metrics to measure progress so that lean and quality objectives are tracked after each cycle. Here is an example of a PDCA outline:

Plan

  • Draw current value stream (VS) map in terms of processes (or activities) OR use future map from previous cycle
  • Calculate times for current VS map
  • Analyze current VS map for waste (delays, additional inspections, extra motions, transport, search time, etc)
  • Make a list of relevant, comparable metrics (Cost of non-conformance, delays, search times, inspection times, quality levels, delivery times, customer feedback)
  • List opportunities for removing such waste by reducing, re-organizing, realigning, training
  • Select easiest opportunities to implement with highest impact first
  • Draw future map based on selected opportunities

Do

  • Prepare action plan for selected opportunities
  • Implement plan by assigning tasks / due dates (no delays)
  • After implementation, let the system run and stabilize
  • Collect data again for measuring progress

Check

  • Analyze data and compare against the “before” set of metrics listed under the Plan phase
  • Provide visuals (charts / figures) to show progress / improvement

Act

  • Update future value stream (this will become the new “current” value stream)
  • List of things you’ve learned from this cycle? Implement in other areas and document for availability and easy access.
  • Goals achieved? If yes, What’s next on the opportunities list? If no, What’s the next goal?
  • Go the next cycle of PDCA

I’ll use an example in Part II.

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