What Is A PDCA/Deming Cycle?

In this blog, you’ll learn the keys to implementing a continuous improvement system and why it’s vital for your organization. There are two essential components every continuous improvement program must have to truly succeed, and you’re going to love hearing about them. So stick around for a fantastic breakdown because we’re about to dive right in. First, let me start by saying there’s a lot of discussion in the industry about continuous improvement, and that’s a great thing! We’re hearing terms like “lean” and how it’s all about eliminating waste and focusing on continuous progress. However, there are some crucial details that can elevate your approach. So, if you want to go beyond general ideas and understand how to actually apply these principles, you’re in the right place.

What is Continuous Improvement?

Continuous improvement isn’t just about making small, incremental changes—though that’s part of it. It’s also about making strategic changes and building a mindset, a habit, and a way of operating. It’s essential for staying ahead in the market, delighting your clients, and improving your processes, which in turn boosts your profits.

Respect for People: A Core Principle

A successful continuous improvement system starts with respect for people. It’s not just about leadership making decisions and forcing them on the workforce. Continuous improvement involves engaging with your team, particularly those on the front lines, who are most familiar with the work processes. The best ideas often come from the ground up. So, respect their feedback and ideas, and consider their input seriously. Continuous improvement should always be collaborative.

Go to the Place of Work

Another important principle is “Gemba,” a Japanese term meaning to go to the place where work is being done. By observing the process in real time, you’ll gain a better understanding of the real issues and areas for improvement. Taiichi Ohno’s method of standing in an “Ono Circle” for hours or days until the true issues become apparent is a perfect example of this.

Stability is Key

To implement a continuous improvement system, your work environment must be stable and organized. Nothing can be improved in chaos. As Paul Akers teaches, stability is foundational for progress. Without a stable environment, any attempt to improve will likely fail.

Standardization: The Foundation of Improvement

Alongside stability, you need standards. Standardization ensures that everyone knows how things should be done. This clarity allows for more effective improvements and easy identification of what’s working or not. Continuous improvement is built on a foundation of standardized processes.

Eliminate Wastes

With stability and standardization in place, you can focus on eliminating waste—whether it’s overproduction, excess inventory, or motion. Recognizing and removing these inefficiencies is crucial for improving your systems and adding value.

Follow PDCA: Plan, Do, Check, Act

PDCA (Plan, Do, Check, Act) is a cyclical process for continuous improvement. You start with a plan, execute it, check the results, and then act on what you’ve learned to improve further. Empower your employees to follow this process themselves, giving them the autonomy to make improvements without waiting for top-down directives.

Focus on the Customer

All improvements should be aimed at enhancing customer satisfaction. Continuous improvement is not just about making changes for the sake of it; it’s about delivering what your customer needs and aligning your improvements with their expectations.

Keep a Long-Term Focus

Finally, keep a long-term focus. Continuous improvement is about making steady progress over time, not solving everything overnight. Break big goals into smaller, manageable tasks, and you’ll be amazed at how much progress you make over time.

The Two Keys to Continuous Improvement

Without a stable environment and a customer focus, continuous improvement will fail. These two elements are the bread in your continuous improvement sandwich. Without them, no matter how hard you try, your system won’t work effectively.

Quick Tips to Get Started:

1. Clarify Accountability: Ensure every employee knows what they’re responsible for in the value chain to the customer.
2. Lead by Example: If you want a culture of continuous improvement, demonstrate it yourself as a leader.
3. Reward Innovation: Recognize and celebrate employees who innovate and contribute to improvement.
4. Issue Challenges: Set specific challenges for teams to solve and improve processes.
5. Follow the Paul Akers Method: Start each day with a quick 5S process, where at least one person shares their daily improvement.
6. Tie Innovation to Promotions: Make continuous improvement a criterion for raises and promotions.

By applying these principles, you’ll not only implement a continuous improvement system, but you’ll also foster a culture that continuously strives to do better.