PDCA-A3 Lean Problem Solving
Problem Solving is the foundation of the Lean office. Continually improving requires continually solving problems - whether these are technical or recurring day-to-day problems. As a Lean tool, A3 reporting addresses the root causes of problems that arise every day at work. When used properly, the PDCA-A3 process dramatically increases the probability of success. Leading companies, such as Toyota, use the PDCA-A3 report to train their employees in a proven and structured problem-solving approach. This 3 day course introduces participants to problem-solving frameworks, tools and techniques, and explores their practical application to common office problems.
The training is designed to:
Provide participants with the understanding and the means for applying the A3 process to drive office improvements. Participants will develop problem-solving skills to reinforce the application of the Plan-Do-Check-Act (PDCA) methodology through practical application.
Upon completion, participants will be able to:
- Learn to identify, classify and define problems
- Be able to analyze and prioritize problems, symptoms and root causes
- Match the right problem-solving process to the problem
- Use a variety of proven problem-solving models, tools and techniques
- “Frame” a problem to gain support and buy in from others in the organization.
- Understand how the A3 process works (PDCA).
- Create an A3 problem report format to “tell the story” of the problem and to guide and structure the problem solving activity.
- Use root cause analysis tools
- Develop countermeasures
- Develop implementation plans
A. Lean Overview
B. Introduction To PDCA and A3 Reports
C. PDCA – 8 Steps To Problem Solving And A3 Reporting
a. Problem Statement
b. Casus and Effect Analysis
c. Roost Causes and Countermeasures
d. Action Plan
e. Results and Follow-up
f. Standardize & Train
g. Recognize/Share Achievement
Knowledge of the following concepts:
- Lean Basics
- Functional (swim lane) process mapping
- Value Stream Mapping
- A-3 Reporting
- Cause & Effect Diagrams
- Affinity Diagrams
- Radar & Relationship Diagrams
- Root Cause Analysis
- Understanding A3 Thinking, Durward K Sobek II, Art Smalley, CRC Press, N.Y, N. Y., 2008
- Managing to Learn, John Shook, LEI, MA, 2008
- Reference: The Memory Jogger II, Michael Brassard, Diane Ritter, GOAL/QPC, Salem, NH., 1994