A3 Training Session

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

How do we get better in our abilities to….

Make Improvements & Communicate ?

• Lets find a proven method…..

• Based on sound principles…..

• With a track record of success…..

The Scientific Method….• Developed in the early 1600’s by Sir Francis

Bacon• Widely used and adopted by the scientific

community from that time forward• Modified and made popular in the mid 1900’s

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

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

• DoRun test

• CheckEvaluate the results of the test

• ActRespond to the results, act uponwhat has been learned

PDCA Cycle

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

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

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)

What does an A3 Report look like?

What does an A3 Report look like?Title: _________________________________________

BACKGROUND• Write according to target audience

• Use VISUAL information as much as possible

• Provide clear understanding of problem/issue• Include historical data, dates, names that might provide insight• List individuals participating in the event

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

GOAL/TARGET• Set a clear goal or target state for the situation• Be clear on the measure of performance• Consider how to collect the data to evaluate effectiveness

ROOT CAUSE ANALYSIS• Show the Root Cause identified• Separate Symptoms and Opinions from cause and effect• Show the tools used in Root Cause analysis (5 whys, Fishbone, etc.)• Identify tests needed to build confidence in Root Cause analysis• Summarize main findings of the Root Cause analysis, Visually if possible

• Use visual methods of explanation when possible

• Use visual methods of explanation when possible

COUNTERMEASURES (ACTION ITEMS)• Make sure action items address the potential Root-Causes

• Clarify implementation order and location clear

• Identify who is responsible for the action item• Be clear on exactly what is expected• Clarify due dates for all actions

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

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

• Plan in advance for data to be collected• Collect data, verify effectiveness of action items• Use the same measures as called out in goal section

FOLLOW UP ACTIONS• Standardize those countermeasures that had a positive effect• Look for similar processes that may benefit from what was learned• Re-address any Root Causes that remain a problem• Plan next steps, may include next “cycle” of PDCA

• May include Gantt Chart (Timeline)

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 Won’t Start:1. Why won’t the car start? Appears to not be getting fuel2. Why is it not getting fuel? No fuel is getting to the fuel injection system3. Why fuel not getting to the fuel injection system? Fuel is not coming from the

pump4. Why is fuel not coming from the pump? The fuel is not getting to the pump5. Why is fuel not getting to the pump? There is no fuel in the gas tank6. Why is there no fuel in the gas tank? The kids don’t want to use their own $

to put fuel in the gas tank.

Root Cause AnalysisIshikawa Diagram

A3 EXERCISEHandwritten, group exercise

“POOR MPG ON KID’S CAR”

Root Cause Analysis– Fishbone Diagram

MATERIAL

METHOD

MACHINE

MAN

Poor Fuel Economy on Kids Car

Poor Maintenance

Poor Driving Habits

Under Inflated Tires

Poor Adjustments

Fast Starts and Stops

Using Wrong Gears

Improper Lubrication

Wrong Fuel Octane

Management

Environment

Extreme Cold Weather

Extreme Hot Weather

No Follow Up

Poor Operator Training

High Altitude

Not Warming Up Properly

Not Trained Properly

Not Warming Up Properly

Improper Use of A/C

Improper Training

Can’t Hear Engine

Poor Hearing

Don’t Understand

Poor Training

Impatient

Always Late

Radio Loud

Don’t Understand

Poor Training

Drive Like friendsDon’t Understand

Poor Training

Don’t Have $

Too Much $ on Gas

Poor MPG

Don’t Understand

Poor Training

Hard to check and fillPoor Design

No Tester Don’t KnowPoor Training

Fuel Mix too Rich

Mech Lacks Knowledge

No Owner’s Manual No Oil ChangeNo $

Wrong OilDon’t know right oil

No Owner’s Manual

Don’t Know Rec OctaneNo Owner’s Manual

Lacks Understanding

Lacks Time

Lacks Patience

Lacks UnderstandingLacks Time

Lacks Patience

What’s the next step?

1.Find an opportunity for improvement

2.Talk to supervisor, get OK to begin work

3.GO FOR IT!Oh, don’t forget to share your A3 with

others, & repeat the cycle