PDCA Cycle: How to Improve Processes in Industry

Failures in industrial processes not only affect productivity but also generate waste and delays.

To avoid this scenario, high-performance companies adopt the PDCA Cycle as the basis for continuous improvement.

Operational challenges that require quick and effective responses arise all the time.

In this context, methodologies such as the PDCA cycle are essential for solving problems and promoting continuous improvements in processes.

Want to know more about the subject? Continue reading to better understand what the PDCA cycle is, how your industry can use it, and the benefits for your company.

WHAT IS THE PDCA CYCLE?

The PDCA cycle, also known as the Deming circle or Shewhart cycle, is a management methodology focused on the control and continuous improvement of processes.

Its name is related to the four steps that comprise it:

• Plan,
• Do,
• Check,
• Act.

According to FIA Business School, “based on the idea that no process is perfect and that improvement is always possible, PDCA provides the conditions for managing its operation with a focus on quality. In other words, the goal is not to achieve perfection, but to get closer and closer to it, using the learning from previous actions”.

The methodology is used in several sectors, especially in industry, because it allows for the systematic control of processes and the solution of problems in a structured manner.

According to Lincoln Gatti, Senior Consultant at Vockan, “although the PDCA cycle is a flexible tool, it is most often applied in repetitive processes with high variability, where you have the opportunity to standardize the process and solve existing problems”.

PHASES OF THE PDCA CYCLE

The PDCA cycle is divided into four stages and each of them is essential for the continuous improvement of the company.

Therefore, it is a cyclical process, that is, after the last stage, the process returns to the beginning, seeking continuous improvements for the company.

The company Sólides explains that “each phase of the strategy is crucial so that the effectiveness of the methodology can be verified at the end of the process. Furthermore, each stage, when well structured, allows for failures and successes to be identified. However, one process must always be followed by the other”.

Understand each stage of the PDCA cycle below:

Plan: diagnosis and planning based on data

In this initial phase, the problem to be solved or the process to be improved is defined.

It involves analyzing data, identifying causes, defining goals and developing an action plan.

The goal is to plan based on evidence, not assumptions.

Do: controlled application of the improvement

After planning, it is time to put it into practice, usually on a small scale (pilot phase).

This stage focuses on implementing the planned solution, collecting data and observing the behavior of the process.

Check: checking results with indicators

Now the results are analyzed, in addition to comparing the current performance with what was planned.

This phase is essential to identify whether the change has actually brought improvements.

Act: standardization or correction of the plan

It is time to make decisions based on the results that have been collected.

If the plan was effective, the new practice is standardized.

If the results were not satisfactory, the plan is revised and the cycle is restarted.

Read also: What is Lead Time? How to Reduce and Optimize Your Production

HOW TO APPLY THE PDCA CYCLE IN INDUSTRY?

Applying the PDCA cycle in industries is an effective way to continuously improve processes, reduce waste, increase productivity and ensure quality.

FIA Business School states that “companies and professionals that use PDCA are always evolving, since the method consists of a cycle of improvement. After planning, executing, checking and acting, they add the newly acquired knowledge to plan again, eliminating errors and waste and increasing their competitiveness”.

The application involves following the four steps in a disciplined and cyclical manner.

For Lincoln Gatti, it is a “flexible tool that can be applied in several areas. It is necessary to plan, defining the problem clearly, communicating with the team and drawing up a small-scale plan to solve the problem. Then, it is necessary to check the results in order to act, adjusting the process”.

Check out below how to apply each step, along with examples of common situations in industrial environments:

Stage	How to apply	Situations
Plan	Identify a problem or opportunity for improvement; Set goals and create an action plan	The quality team notices an increase in the number of reworks due to welding failures. Therefore, they create a plan that involves: machine calibration, operator training and review of welding parameters, in addition to setting goals
Do	Implement the plan on a small scale or in a pilot phase; Train the people involved	The plan is put into practice in one of the cells of the assembly line. The robotic welding machines are recalibrated and the operators are given technical training, in addition to predictive maintenance of the machines
Check	Compare the results obtained with the established objectives/goals; Use indicators (KPIs), control charts, comparative reports	After 2 weeks, the results of the pilot are monitored. Data is collected on the number of defective welds, rework rates are compared before and after the intervention, and a meeting is held with the technical team and operators to analyze the results obtained
ACT	If the plan worked, standardize the improvement; If it didn’t work, analyze failures and restart the cycle with adjustments.	With positive results, actions are standardized and implemented in all cells of the line. Operational standards are updated, training is expanded for the entire team and a continuous system of control and improvement of weld quality is implemented

5 CHALLENGES OF THE PDCA CYCLE AND HOW TO OVERCOME THEM IN INDUSTRIAL ENVIRONMENTS

During the implementation of the PDCA cycle, industries may face several practical challenges that compromise results if they are not well managed.

These challenges are related to both organizational culture and operational structure, and can be overcome with planning, training and leadership.

Below are the main obstacles and ways in which your industry can overcome them:

Lack of or poor quality of data

The planning phase is based on accurate data and not on assumptions, as this can compromise the rest of the cycle.

Invest in measurement and data collection systems and train employees to record and interpret information correctly.

Poorly conducted execution

If the plan is not well communicated or implemented, the results will not reflect the real potential for improvement.

Therefore, it is essential to adequately train the team involved and constantly monitor during execution.

Ineffective verification

Verification is often done superficially, without in-depth analysis.

Use previously defined performance indicators (KPIs) and compare before and after based on objective data.

Organizational culture resistant to change

Changes may not be well accepted, especially if they involve new work methods.

Promote a culture of continuous improvement, value small victories and give visibility to positive results.

Lack of standardization after improvement

When the solution works and ends up not being incorporated into the routine, the company returns to the previous stage.

Update standard operating procedures (SOPs), train the team to follow the new process and conduct internal audits to ensure standardization.

Read also: How to Apply Agile Methodologies in Industry and Increase Operational Efficiency

5 BENEFITS OF THE PDCA CYCLE FOR INDUSTRIES

Industries need to continually seek ways to improve their processes, reduce waste, increase productivity and ensure the quality of their products.

By adopting the PDCA Cycle, companies start to make decisions based on data, involving teams in problem-solving and promoting a culture of continuous improvement.

We have listed five benefits that this methodology can provide to companies. Continue reading to find out what they are.

Continuous process improvement

PDCA is cyclical, which means that at the end of each cycle, there is learning and evolution.

This allows industrial processes to be constantly analyzed and improved.

Reduction of waste and rework

By identifying the causes of problems based on data, PDCA helps to eliminate failures, rework and losses, aligning with the principles of Lean Manufacturing.

Increased productivity

Continuous improvements, elimination of bottlenecks and greater efficiency in processes result in increased productivity.

Standardization and control

At the end of the cycle, successful practices are documented and standardized, facilitating team training and ensuring consistent results.

Data-based decision-making

Each stage of PDCA requires analysis of concrete information, avoiding decisions based on opinion, making management more accurate.

How ERP QAD BR+ Helps Your Industry Put PDCA into Practice

Applying PDCA requires more than a desire to improve — it requires data, discipline and integration between areas. That’s where QAD BR+ comes in.

With it, your industry can connect planning, execution and analysis on a single platform, with real-time data and well-defined flows.

The result? More predictable processes, faster decisions and a truly sustainable improvement routine.

See what QAD BR+ helps deliver in practice:

• Total control over processes and indicators
• Reduction of failures and rework
• Standardization of what works
• Agility in decision-making

Talk to our experts and understand how QAD BR+ can apply the PDCA cycle in a real and efficient way in your operation.