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Back 2 School > Manufacturing > Best Practices In Manufacturing

The PDCA Cycle Of Systematic Development

PDCA is an acronym for PLAN, DO, CHECK and ACT.

It is very simple, easy-to-use and highly effective means of managing anything and everything!

The PDCA cycle is also known as the Deming Cycle, the Deming wheel of continuous improvement spiral.

Its origin can be traced back to the eminent statistics expert Mr. Walter A. Shewart, in the 1920’s. He introduced the concept of PLAN, DO and SEE.

The late Total Quality Management (TQM) guru and renowned statistician Edward W. Deming modified the SHEWART cycle as: PLAN, DO, STUDY, and ACT.

Along with the other well-known American quality guru-J.M. Juran, Deming went to Japan as part of the occupation forces of the allies after World War II. Deming taught a lot of Quality Improvement methods to the Japanese, including the usage of statistics and the PLAN, DO, STUDY, ACT cycle.

The subsequent results of the Japanese industry, business and government are now a part of business history and well documented internationally.

The Japanese modified Deming’s coinage of PLAN, DO, STUDY and ACT to the present-day, universally accepted PDCA acronym for systematic management.

Moreover, many companies in Japan, USA, Europe and India too have already proven beyond doubt the practical, sustained business benefits accruing from this simple and effective method.

Another compelling reason is that it can be easily tried out (there is no financial cost, only mental and physical efforts are required!) and practised at any level and magnitude and the obvious advantages can be tasted through a test-recipe before ordering the full course!

PDCA has varied applications. A few are listed below:

  1. For daily routine management-for the individual and/or the team.
  2. For problem-solving process.
  3. For project management.
  4. For continuous development.
  5. For vendor development.
  6. For human resources development.
  7. For new product development.
  8. For process trials.

Belief in PDCA, coupled with diligent application will ensure successful implementation. Unlike most other management concepts and jargons, the PDCA concept is used by all of us, knowingly or unknowingly, in our own unique ways.

The simplest domestic example is the shopping-list made by a housewife.

In a business environment, the simplest example is the written or unwritten plan made by every individual, at the start of a new day.

However, the important question is: Do we implement this known method of systematic management, CONSISTENTLY, AT ALL TIMES?

All of us plan most of our activities, and we certainly implement most of these plans, in full or in part (This is the DO portion of PDCA).

However, do we review (CHECK) our implementation of the plan often and with ruthless thoroughness?

Even if we have done the reviews and reached a conclusion, do we ACT on this information in an effective and timely manner?

The PDCA methodology of Systematic Management is the part of any Total Quality Management Programme for the simple reason that the answer to the two questions in the previous paragraph are not found to be satisfactory in most business organisations.

Indian examples of some companies using TQM and PDCA are:

  1. WIDIA, Bangalore.
  2. MODI XEROX, Rampur.
  3. Crompton Greaves, Mumbai.
  4. TISCO, Jamshedpur.

Try it out, by maintaining a daily PDCA logbook for ten days. Guaranteed that you will become a firm believer and lifetime user of PDCA, thereafter.

 

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