A3 Training Session

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A3 Training Session
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Introduction.

• We all are involved in

• Looking for ways to save resources

• Finding ways to improve quality

• Fixing problems

• Finding better ways to do things

• In each case, we also need to communicate share

• Report to supervision

• Help others learn from our success and failures

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• How do we get better in our abilities to.

Make Improvements Communicate ?
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• Lets find a proven method..

• Based on sound principles..

• With a track record of success..

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The Scientific Method.

• Developed in the early 1600s by Sir Francis Bacon

• Widely used and adopted by the scientific
  community from that time forward

• Modified and made popular in the mid 1900s by
  Walter Shewhart and Edward Deming, becoming the
  PDCA Cycle.
• These men are known as the Fathers of Statistical
  Quality Control and Quality Control respectively

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PDCA Cycle

• Plan

Understand the problem/situation, create plan to
see if assumptions are correct

• Do

Run test

• Check

Evaluate the results of the test

• Act

Respond to the results, act upon what has been
learned
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• The power in using this method comes from

• Following the standard method, which encourages
  accuracy and completeness

• Repeating the cycle, upon completion, once a
  hypothesis is confirmed (or negated), executing
  the cycle again will extend the knowledge
  further. Repeating the PDCA cycle can bring us
  closer to the goal, usually a perfect operation
  and output Wikipedia

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• How are the Scientific Method and A3 Reporting
  related?

• The A3 Report is a picture of the PDCA cycle

• And is a great tool to share the progress and
  results of the efforts to others

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A3 Report

• A3 represents the size of the paper (11 X 17)

• Is meant to guide through the PDCA cycle

• Is not meant to require significant efforts to
  document the project, do by hand at first

• Documents each of the PDCA steps, on a high level

• Is meant to be very visual

• Is meant to contain data to support understanding
  of the problem (plan) and results of the
  experiment (Check)

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What does an A3 Report look like?
DO
PLAN
CHECK
ACT
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What does an A3 Report look like?
Title _________________________________________
COUNTERMEASURES (ACTION ITEMS)

• Make sure action items address the potential
  Root-Causes

BACKGROUND

• Identify who is responsible for the action item

• Write according to target audience

• Be clear on exactly what is expected

• Provide clear understanding of problem/issue

• Clarify due dates for all actions

• Include historical data, dates, names that might
  provide insight

• Clarify implementation order and location clear

• List individuals participating in the event

• May include Gantt Chart (Timeline)

• Use VISUAL information as much as possible

CURRENT CONDITIONS

• Depict an overview of the current process or
  system

• Highlight key features in the current state

• Identify what you know about the problem. What
  it is, is not?

• Use data, numbers to further explain the current
  situation

• Use visual methods of explanation when possible

GOAL/TARGET
EFFECT CONFIRMATION

• Set a clear goal or target state for the
  situation

• Determine ways to confirm effect, by each root
  cause if possible

• Plan in advance for data to be collected

• Be clear on the measure of performance

• Collect data, verify effectiveness of action
  items

• Consider how to collect the data to evaluate
  effectiveness

• Use visual methods of explanation when possible

• Use the same measures as called out in goal
  section

• Show data and how it confirmed, or not, action
  items

ROOT CAUSE ANALYSIS
FOLLOW UP ACTIONS

• Show the Root Cause identified

• Standardize those countermeasures that had a
  positive effect

• Look for similar processes that may benefit from
  what was learned

• Separate Symptoms and Opinions from cause and
  effect

• Re-address any Root Causes that remain a problem

• Show the tools used in Root Cause analysis (5
  whys, Fishbone, etc.)

• Identify tests needed to build confidence in
  Root Cause analysis

• Plan next steps, may include next cycle of PDCA

• Summarize main findings of the Root Cause
  analysis, Visually if possible

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Root Cause Analysis

• Often the most missed step
• Various tools to help get to the Root Cause
• 5 Whys ask the question why at least five
  times, until arriving at the root cause
• Example The Car Wont Start
• Why wont the car start? Appears to not be
  getting fuel
• Why is it not getting fuel? No fuel is getting
  to the fuel injection system
• Why fuel not getting to the fuel injection
  system? Fuel is not coming from the pump
• Why is fuel not coming from the pump? The fuel
  is not getting to the pump
• Why is fuel not getting to the pump? There is no
  fuel in the gas tank
• Why is there no fuel in the gas tank? The kids
  dont want to use their own to put fuel in the
  gas tank.

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Root Cause AnalysisIshikawa Diagram
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A3 EXERCISEHandwritten, group exercisePOOR
MPG ON KIDS CAR
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Root Cause Analysis

• Fishbone Diagram

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Whats the next step?

• Find an opportunity for improvement
• Talk to supervisor, get OK to begin work
• GO FOR IT!
• Oh, dont forget to share your A3 with others,
  repeat the cycle