What is the Act of rotating PDCA in TQM? - Mechstudytips

Act of rotating PDCA

(1) The plan

When the Managing Points (MP) and Checking Points (CP) of a functional head are deployed to his/ her subordinate, then the CP of the HOD becomes the objective of the subordinate. We can say that the Managing Points and Checking Points when deployed, becomes Individual objectives and key strategies become Individual action points.

The Individual objectives are owned by the subordinates and the Procon Achieving the objectives is known as the rotation of PDCA.

The plan of PDCA is the objectives owned by individuals. They can be stratified in terms of PQCDMS.

(2) Execution of plans:

The plans are executed by following Standard Operating Procedures (SOP) The plans are often accomplished by engaging teams such as QCCs, SITs and CFTs. The teams execute projects of improvements.

(3) Checking and analysis:

1) Visual Control System (VCS)

The status of the progress is checked on an hourly/daily/weekly basis. That is why this process is called Daily Management. Keeping in mind the famous dictum that 'what gets measured, gets done, the status of the objectives is tracked using visual control charts. This system of monitoring is known as Visual Control System (VCS)

• The VCS is the way of tracking the performance using statistical tools such as, Check Sheets, graphs, charts etc., in an appropriate manner in order to grasp the current status. The VCS system is based on the TQM principle of Fact-based Management
• Colour codes are used to highlight the achievements and gaps.
• The typical formats used by production departments (Hourly performance) is used for collecting data and  (Weekly performance) is used for Pareto analysis and finalizing the 3TS - Theme, Team, and Targets.

2) Use of QC Story

The gaps captured through the visual control system are analyzed using QC Story methodology. For the methodology and also the tools (T20)

3) The use of 3W1H

The QC tool namely 3W1H is used as a part of QC Story steps. However, 3W1H can also be used as a stand-alone technique for resolving simpler issues. 

• 3W1H is an effective tool for focusing on action to be taken for all problems
• State the problem clearly under the column What. Give details, if required
• Find out the root cause by proper analysis through a QC Story. If not Story. If not
• ask "Why" 5 times and arrive at the root cause
• After arriving at the root cause, list the actions required to be taken in the 'how' column. They are of three types:
• a) Immediate actions to quench the fire
• b) Corrective actions which are systemic actions with long term views and
• c) Preventive actions which are the horizontal deployment of corrective actions in other applicable areas to proactively prevent the occurrences of non-conformity from happening.
• At the next meeting, review the 3W1H of the previous day and arrive at the new 3W1H, if required
• Generally Who' should be a single person and 'When' should be a specific date
• You can also add 'From' & To' in the column What' to indicate the level of improvement aimed at
• Track the completion points and assess the Hit Ratio as an index of accomplishment (Number of points completed to Number of points raised). This would serve as an indication of Excellence in Execution.

Note: While writing the 'how use verbs such as Introduce, Implement, Modify, Change, Increase, Decrease, etc. These are action verbs. Avoid using words such as Ensure, Monitor Control, Improper, Insufficient, Inadequate, etc. These are words lacking inexactness.

(4) Action Based on Analysis:

The review points coming out of 3W1H are listed in the Individual Action Plans for the concerned persons to take action. They are the 'how of Individual objectives’

• An individual Action Plan is the accumulation of the action points of the Individual objective
• Effective tool for deploying the action plans emanating from 3W1H
• Owned by individuals, Individual Kaizens and accumulation of Kaizens
• Each person in the company lists down improvement plans with a target date.After accomplishment, he/she affixes a star or a tick mark against the date. 
• Individual Action Plan can be used like the Hundred Item Improvement Plan (HIP) as advocated in the book Canon Production System for accumulating all improvements planned and executed by an individual
• Pride and satisfaction are their natural rewards. Companies can also take these improvements into consideration while  assessing the annual appraisal of individuals
• Individual Action Plan is the inspiration poster, reminding the individuals to focus on the actions and targets constantly

(5) Conclusion:

1) The outcome of Rotating PDCA

The act of rotating PDCA flows back the information to revise the Standard Operating Procedures and the link between Standardization and Daily Management is, thus firmly established

When the PDCA and SDCA cycles are rotated in tandem based on facts with appropriate use of TQM tools and with a mindset embedded in TQM culture, then the process becomes a successful art. This is the crux of continuous improvement of our daily activities, leading to enduring customer satisfaction and superior business results.

2) Role of Total Employee Involvement (TEI)

The teams such as QC circles and Supervisory Improvement Teams are engaged in taking projects to eliminate the gaps, captured during the daily reviews. The rotation of PDCA is like a nuclear chain reaction of the self-sustaining source of enormous energy, especially when it is done by teams.

Workplace improvements are carried out by QC Circles.

Supervisory Improvement Teams (SIT) and Cross-Functional Teams (CFT) are engaged to take action on major gaps so as to achieve functional objectives-on time.

3) Improvements: are they continual or continuous?

When the PDCA and SDCA cycles are rotated in tandem and the process is viewed at the project level, then it is right to call the process 'continual'.However, when viewed from the organizational level, where numerous improvements are inundating beneficially, then the process is called 'continuous'. 

Remember the Tamil saving: 'small drops create a huge deluge'