One way to describe the A3 is as “standardized storytelling” which refers to the ability of A3s to communicate both facts and meaning in a commonly understood format. Like any narrative tale, an A3 tells a complete story, with a beginning, a middle and an end, which can be traced from the upper left-hand side to the lower right side. Because readers are familiar with the format, they can focus easily on the matter contained. It becomes the basis for reaching a shared understanding.

A3 can be completed in step by step approach. There are Eight steps to complete A3 process.

A3 Eight Steps

Step 1. Clarify the problem

Why am I looking at this problem? What is the problem? Who is interested in the problem? What benefit does solving this problem have for me? How does it help to address the goals of the business?

• Select the area/process & open A3 in Excel
• Elect a leader
• Form the team (stakeholders)
• Train the team in the 8 step approach
• Identify all stakeholders
• Define the problem in terms of impact on the customer & stakeholders.
• Conduct is/is not analysis
• Conduct a gemba walk and take photographs

Step 2. Break down the problem

What is the size of the problem? What data do I have? What are the component parts of this problem? How much will I address at this point?

Draft a summary map of process, or machine schematic e.g.

• SIPOC
• Spaghetti map
• process map
• blueprint
  

Measure key features of the process problem e.g.

• Bar chart
• line graph
• Run chart

Step 3. Set the targets

What outcome do I want? Visualise the desired results. Using the data, set a measurable and realistic goal.

Goal Format: Action verb + object of the action + from “current state” + to “future state” by “date”

e.g. Decrease average manufacturing lead time for product X from 10 days to 2 days by 31 January 2014″

Draft the outline project plan by when the project will be finished
Allocate time lines & responsibilities (e.g. summary Gantt chart)
Develop draft financial gains and get finance approval (if appropriate)

Step 4. Analyse the root cause (Fishbone, 5 Why’s, Pareto, etc.)

Clarify the root cause. Consider as many potential cause factors as possible.

• Interviews
• praetor charts
• Data stratification
• 5 whys
• Cause and effects analysis
• Process Capability Analysis
• Scatter diagrams
• Box plots
• Regression & Correlation
• FMEA

Identify areas for improvement

Step 5. Develop countermeasures (Prioritize)

List as many potential countermeasures as possible. Identify an effective countermeasure that directly addresses the root cause. Prioritise issues. Identify and make ready all tools an equipment for change in advance of the of the event.

• Brainstorming
• Priority list
• Gantt chart
• Pilot timetable

Step 6: See countermeasures through

Select the most practical and effective countermeasure(s). Create a clear and detailed action plan. Implement quickly.

• Gantt chart – tasks and timelines
• Detailed timetable of events
• layout changes
• SMED
• visual workplace
• error proofing
• FMEA

Step 7. Monitor results and processes

Monitor progress and report findings to stakeholders. It may require more than one attempt to get the desired result. Mistakes are an important part of the learning process.

• Run chart
• Control chart
• Process capability analysis

Conduct post implementation review – snag list & action items

Step 8. Standardize successful processes

Document the new process and set as new standard. Share the new standard through Horizontal deployment. Reflect and celebrate success.

• Train personnel in new way of doing things
• Standardise new processes, update procedures, implement visual management
• Use control charting to prove results and maintain discipline in the area
• Confirm the financial gains (if required)
• Present to senior management
• Recognise and reward the team
• Reflect on lesson learned

Start the next Improvement!