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Process Improvement Consultation




Lean Management

PDCA – The Plan Do Check & Act approach is a continual improvement process approach which aims to have continuous improvement in an organization for its any of the processes. This is also called as Deming cycle or continual improvement cycle. In the plan stage, the objectives and procedures are well planned and established. In the Do stage, the actual output is being generated as per the procedure created. In the Check stage, the outputs that are created are compared against the plan & objectives for process monitoring and performance analysis. From this check, we can get to know if there are any deviations against what has been plan. In the Act stage, if the is a positive deviation, then next level objectives are set. If the deviations are negative, then the organization needs to perform a root cause analysis to determine the reasons for not achieving the targets and targets may be revised.

Japanese term of improvement aims from having small improvements in the aspects of Men, Machine, Material & Method (4Ms) which could be initiated from all levels of people in the organization. It considers people, processes and procedures where there could be a possibility of identifying and implementing smaller continual improvement on all the four areas. As everyone is involved, it increases the morale of the people and they find out ways of creating the deliverables in the most economic as well as shortest possible timeline. It can be combined with other lean management concepts for to be implemented in the most effective way in the organization

An effective workplace management system which makes the people to perform the activities effectively, efficiently & safely. 5S in short can be defined as “a place for everything, and everything in its place”. Some of the benefits of implementing 5S in an organization are: reduced cost, increased productivity, higher quality, safe working environment, increased morale, employee satisfaction etc. The 5S of this concepts are: Seiri – Sort everything, Seiton – Set in order, Seiso – Shine, Seiketsu – Standardize and Shitsuke – Sustain. This makes the workplace to be more effective for anyone to identify anything in the workplace, hence it reduces or eliminates valuable workmen time in searching for some tools or equipment.  When the workplace is clean & shine, it provides a safe working environment for the people working in the organization.

It is the process of identifying and eliminating wastes (non-value adding activities in the processes). While we aim to produce the output in a more efficient way, knowingly or unknowingly there are many processes or activities which do not add any value or not so important for the customer. In the concept of lean manufacturing rooting from Toyota production system there are seven types are waste. They are: Transport, Inventory, Motion, Waiting, Over processing, Over production and Defects. While these are considered not adding any value to the business process, we can build an effective lean management system with the processes of aiming on understanding the value that we need to deliver to the customer and other related stakeholders, identifying effective processes that creates value and implementing an effective processes flow using value stream mapping, work only when there is a need – creating a pull system – this will avoid over production, aim for continuous improvement of the system

PDCA - Plan Do Check Act

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