I am familiar with the Toyota A3 Report as I have had to use this a few times at my current job as an Industrial Engineer. Like many of my peers from class have stated, the Toyota Production System (TPS) is an excellent example of lean manufacturing studied by many professors over many courses at Worcester Polytechnic Institute. As the article points out, while many have studies the best practices for Toyota manufacturing, little has been discovered about the cultural influence of Toyota production environments.
In addition to the A3 report, I often rely on the Deming Cycle & DMAIC methodologies for optimized problem solving. In fact, I sense a clear relationship between PDCA and A3; so much so that I often combine these methodologies in my own practice. The Deming Cycle, created by Edward Deming, is a problem solving approach based on a four letter acronym, PDCA: Plan, Do, Check, Adjust.
- Discover the current condition of your problem: Who/What/When/Where/Why?
- Get BEFORE Metrics in order to measure success of problem solving methodology.
- Analyze the current condition as basis for setting improvement goals.
- Set SMART Goals meaning set goals that are Specific, Measureable, Achievable, Relevant, and Timely to the Business Setting
DO
- Introduce countermeasures to solve the original problem and achieve goals.
- Complete action plans for countermeasure development and/or implementation.
- Engage operators for increased buy-in.
CHECK
- Analyze the results of the actions against original goals and problem.
ADJUST
- Revise countermeasures when needed for optimal problem solving.
- Standardize best practices to ensure learning and operator buy-in long term.
- Complete all follow-up actions.
- Repeat cycle for continuous improvement.
The biggest lesson we can learn from Toyota’s A3 Report is that engaging all levels of the work force with simple, transparent communication increases organizational buy-in and sustainable improvements.
The PDCA approach is very interesting and really does overlay the A3 approach nicely. Each step is methodical and ultimately explores the entire picture rather than one segment. As you stated in your last paragraph, Communication is key, so involving all levels and organizing innovation throughout the company will really pay out in the long run!
ReplyDeleteWow I am amazed that you use the A3 report at work. I have never seen this in use before and I am quite excited about the potential that this methodology possesses. It may not be the most efficient way of solving problems....but it really ensures that employees are trained the right way and there is alignment in objectives across the company. I think it is a great tool for mentoring employees . Key to the A3 report is the brevity. It really trains employees to condense the problem to essential elements for proper analysis.
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