How to adopt Continuous Improvement in your company with PDCA cycle?

The PDCA is a cycle that is repeated countless times, and each time this cycle is repeated, it is easier to achieve the established goals through continuous improvement of the production process

This continuous improvement allows the company to better adapt to market changes and customer needs more quickly, always based on concrete data and analyzed in a more rational way.

Although a process can have 80% success rates, a positive number for most areas, the other 20% can mean high material waste rates, high rework rate, among other aspects that damage and cost resources and do not add no value to the final product.

Used in the Toyota Production System, the PDCA focuses on lean production, based on rational management of the production process.

This provides advantages such as:

• reduction of unnecessary costs;
• revenue maximization.

It's a really great strategy and it can help a lot in a business, making it profitable and easier to manage.

The PDCA Cycle

It is essential that companies adopt a strategic posture regarding their positioning, creating goals that will ensure their growth and not their stagnation. One of the best known methods for creating these goals and generating continuous improvement within the industry is the PDCA cycle [Plan, Do, Check, Act). PDCA [Plan (Planejar) – Do (Fazer) – Check (Conferir) – Act (Agir]).

Plan: Establishes the expectations of a company in relation to a certain process. If the company's goal is to reach a 100% success rate in its production, this is the point that the goals have to attack at this stage;

Do: Implement the plan determined in the planning stage. Collect data for mapping and analysis of next steps. Develop target indicators, which are always determined at the exit;

Check: Study the results generated via indicators and numbers. This step depends on other highly measurable steps. Results rate is not measured by employee “feeling”: success lies in developing more effective production control methods, and determining how much more effective they will be;

Act: Corrective measures that go back to the first step of the process. At this point, the initial improvement project no longer exists: it has been improved, adapted and has become a personality apart from what was known as a process in the company.

The main objective of the PDCA Cycle is for it to be really cyclical. Iteration (or repetition) is what guarantees that, at each step, more problems will be solved and that there will, in fact, be an improvement in the process.

PDCA Advantages:

• Constant improvement of process results;
• Decrease in the margin of error in the decisions taken;
• Increased team motivation to achieve established goals through a rational production process;
• Increased productivity through greater control of the objective x achieved result ratio;
• Increased competitiveness with the development of a solid database;
• Resource saving;
• Systematization of results;
• Problems solution.

Care to be taken in implementing the PDCA to prevent it from becoming disadvantageous:

• Implementation of PDCA without planning;
• Stop using the methodology after completing the first cycle;
• Do not fix detected problems;
• Do and do not check the collected data;
• Not having mastery of the methodology;
• Not having qualified professionals to operationalize the PDCA.

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Do you want to know more about how to apply a good PDCA cycle in your company to reduce raw material waste and improve the Supply Chain?

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