The A3 process was developed by Toyota as problem solving tool to enhance learning, collaboration, and personal growth of the workforce. It is derived from the particular size of paper used for outlining ideas, plans, and goals throughout the A3 process.
The A3 process provides structure for continuous improvement efforts. It also provides a basis for documentation of process improvement initiatives. In addition to project work, organizations make use of the A3 process to manage their continuous improvement efforts.
A3 reports can be used in the following ways:
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The following 10 steps outlines the processes involved in applying the A3 problem solving approach:
This is the first of the A3 approach. In order to be able to solve a problem, such a problem has to be first identified.
The second stage of the process involves capturing and analysing the current state of the situation. This could be done by:
This requires getting to the true cause of the problem using tools like the 5 “Whys”.
These involves gathering ideas for tackling the problem; the changes to be made to your processes that will move the organization closer to ideal by addressing root causes.
In A3 approach, the target measure is communicated through a process map.
Once the target state is determined, a plan on how to achieve it should be devised. The plans should include:
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The objective of any systemic improvement is that it improves the part of the system in question; hence everyone who might be affected by the implementation or the target state should be accordingly carried along in the conversation before changes are made. It might be important to inform executives and other stakeholders who might be impacted by the work.
The agreed upon implementation plan should be followed and executed, observing opportunities for improvement along the way.
It’s critical to measure the actual results and compare them to your predictions in order to learn from any deviation. Alter the process as necessary and repeat implementation and follow-up until the goal is achieved.
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Adebayo is a thought leader in continuous process improvement and manufacturing excellence. He is a Certified Six Sigma Master Black Belt (CSSMBB), Digital Manufacturing Professional and Management Systems Lead Auditor (ISO 9001, 45001 & ISO 22000) with strong experience leading various continuous improvement initiative in top manufacturing organizations.
You can reach him here.