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White Belt · 14 min

PDCA: the Check is the part everybody skips

After this you can

  • run a PDCA cycle on a small change and state what I would measure at each step.
  • collect data against a written plan without changing how the work is done.

Assumes you have done DMAIC: what each phase produces and why the order holds and Mapping the gaps, not the boxes.

The problem

A clinic started reminder calls in week 13 to reduce missed appointments. The three weeks that followed were 28, 30 and 32 — against a pre-change median of 37.5, a drop of about 20%, and what the clinic called the three lowest weeks of the year. The trial was declared a success, the calls were rolled out permanently at a cost of half a full-time post, and the reporting moved to monthly. Twelve weeks later the figure was back where it started. Nothing had changed in week 13. The three low weeks were ordinary variation, and there had never been a plan for how to tell.

The idea

PDCA — Plan, Do, Check, Act — is a cycle for making a change and finding out whether it worked. Deming called it a cycle for learning, and the distinction matters: the output of a PDCA is knowledge, not a completed action.

Three of the four steps are done routinely everywhere. Check is skipped almost universally — not deliberately, but because by the time the change is in, everyone has moved on, and because nobody decided in advance what checking would consist of.

Plan

State the change, the prediction, and how you will know.

The prediction is the load-bearing part, and it is what distinguishes PDCA from simply doing things. Not "this should help" — "missed appointments will fall from around 37 a week to under 30, and we will see it within six weeks". A prediction you write down can be wrong, which is the only way the cycle produces learning.

Then decide what you will measure, before the change, and write a data collection plan:

FieldWhy it is there
WhatWith an operational definition — what counts as a missed appointment?
HowThe instrument: which system field, which report, exported by whom
Who collects itA named person, not "the team"
When and how oftenWeekly for how many weeks — decided now, not when the data looks good
How manyEnough points for the rules to have power. Below ten, a run chart cannot detect anything
StratificationWhat else to record so you can split it later: shift, site, clinic type

The last row is the one people regret omitting. Recording the clinic alongside the count costs nothing at the time and is impossible to reconstruct afterwards.

And a rule that must be written down: how will you decide? "We will conclude it worked if the run chart shows a shift — six or more consecutive weeks below the median." Decided in advance, this is a test. Decided afterwards, it is a description of whatever happened.

Do

Run the change small and reversible. A trial on one clinic for eight weeks tells you almost everything a full roll-out would, at a fraction of the cost and with the option of stopping.

And here the discipline from data collection applies: collect the data as the plan says, without changing how the work is done. Standing over someone with a clipboard changes what they do — everyone works to the standard while being watched. Use data the process already produces where you can, and where you cannot, tell people what you are recording and why. Observation that people know about is far less distorting than observation they suspect.

Check

Compare what happened with what you predicted. Not with what you hoped, and not with last month.

This is where the run chart earns its place. Two points cannot separate signal from noise; neither can three. The rules — six consecutive points one side of the median, too few runs — are precisely the tools for asking whether the change did anything, and they need enough data to work.

"It did not work" is a successful PDCA. You now know something that cost you eight weeks and one clinic instead of a permanent half-post. The cycle that produces no learning is the one where nobody checked.

Act

Three honest options: adopt it, adapt it and run another cycle, or abandon it.

Abandoning is the option organisations find hardest, because a change that has been announced acquires defenders. This is exactly why the prediction and the decision rule are written down in Plan — they were agreed before anyone was invested in the answer.

Worked example

The clinic's own data, all 24 weeks, with the trial starting at week 13:

37, 39, 38, 29, 41, 32, 30, 40, 35, 31, 41, 4028, 30, 32, 26, 38, 34, 34, 37, 37, 40, 37, 27

What the clinic did. Compared the first three post-change weeks (28, 30, 32) with the pre-change median of 37.5. About a 20% fall, three weeks running. Declared success.

What the run chart says. Median of all 24 weeks: 36. Twelve runs, where ordinary variation over this split would give somewhere between 8 and 18. No shift, no trend, no signal of any kind. The variation across the whole two-thirds of a year is consistent with a single stable process — and the dataset was in fact generated from one, with no change in it anywhere.

Look at what the pre-change period alone contains: 29 in week 4, 30 in week 7, 31 in week 10. The weeks the clinic called "the three lowest of the year" were nothing of the kind — 26 in week 16 and 27 in week 24 are both lower — and they were not far outside a range the process had been producing all along.

And underneath the headline, the arithmetic was mean-before against mean-after: 36.1 against 33.3. That is a real arithmetic difference, and it is what two samples from the same stable process routinely look like. Any two twelve-week halves of this series would differ by something.

What a Check would have cost. The decision rule — "a shift of six or more consecutive weeks below the median" — takes one line in the plan and six weeks to evaluate. The clinic had the data; what it did not have was a rule written down before the answer arrived.

What Act should have been. Abandon, and it would have been the most valuable outcome available: half a post saved, and the knowledge that missed appointments are driven by something the reminder calls do not touch. Instead the calls became permanent and the real cause was never looked for.

Dataset: ds-pdca-reminder-calls — the same data loads in the tool below, so you can reproduce every figure here yourself.

Your turn

The run chart opens with all 24 weeks.

  1. Confirm: median 36, twelve runs, no signals. The tool states plainly that no signal is not the same as "the process is fine".
  2. Now delete weeks 16 to 24, leaving only the three weeks the clinic looked at plus the pre-change period. Fifteen points, and still no shift — the run of consecutive weeks below the median is three, not six. Even the clinic's own truncated view did not support the conclusion it drew.
  3. Paste a series where the change did work: keep weeks 1–12 and replace weeks 13–24 with 24, 22, 25, 21, 23, 20, 24, 22, 26, 21, 23, 22. The shift rule fires immediately, and the runs test with it. This is what a working change looks like, and it does not need interpretation.
  4. Compare how the two conclusions feel. The real one is not subtle. If you find yourself arguing about whether a change worked, that is usually the answer.

Run Chart

practice
Run chart of 24 missed appointments values in time order. Median 36. No rule signals: the variation is consistent with a single stable process.Longest run on one side of the median: 4 points.median42.824.2Week 1Week 24
Points in time order — never sorted. The centre line is the median, not a target. Squares mark points inside a rule signal.
Show the data behind this chart
Run chart of 24 missed appointments values in time order. Median 36. No rule signals: the variation is consistent with a single stable process.Longest run on one side of the median: 4 points.
#Labelmissed appointmentsVs median
1Week 137above
2Week 239above
3Week 338above
4Week 429below
5Week 541above
6Week 632below
7Week 730below
8Week 840above
9Week 935below
10Week 1031below
11Week 1141above
12Week 1240above
13Week 1328below
14Week 1430below
15Week 1532below
16Week 1626below
17Week 1738above
18Week 1834below
19Week 1934below
20Week 2037above
21Week 2137above
22Week 2240above
23Week 2337above
24Week 2427below

Points

24

Median

36

Longest run

4 points

Above median
12
Below median
12
Runs observed
12
Expected range
8–18

No signals. Nothing here is distinguishable from ordinary variation.

No signals. That means the variation you are looking at is consistent with a single stable process — NOT that the process is good, and not that nothing can be done. A stable process delivering the wrong result will keep delivering it until the process is changed.

One observation per line, oldest first: Week 1, 34 — or just the number. Do not sort it. The order IS the data.

How this is calculated

The centre line is the median, not the mean — a single extreme value moves the mean and would drag the centre line towards the very point you are trying to notice.

  • Shift — 6 or more consecutive points on one side of the median. Points sitting exactly on it are skipped, neither extending nor breaking a run.
  • Trend — 5 or more consecutive points all rising or all falling. Shown, but the weakest of the three: it fires on random data more often than people expect.
  • Too few / too many runs — the number of times the series crosses the median, compared against the exact distribution of the number of runs. The critical values here are computed from that distribution rather than looked up in a table.

A fourth classic rule — an “astronomical” point obviously unlike the rest — is deliberately not automated. It is a judgement about the process, and any threshold would get it wrong in both directions.

Source: Provost & Murray (2011), The Health Care Data Guide, Ch. 3 for the rules; Swed & Eisenhart (1943), Annals of Mathematical Statistics 14(1) and Gibbons & Chakraborti, Nonparametric Statistical Inference 5e §3.2 for the runs distribution.

Saved runs can be attached to a project deliverable as evidence. Both what you entered and what the tool computed are stored, so the result can be checked again later.

Check yourself

No hints. Wrong answers are explained, not softened.

A team plans a change and writes 'we expect this to improve things'. What is missing, and why does it matter?

You need three weeks of cycle-time data. Standing with a stopwatch would change how people work. What is the best approach?

A trial's data shows no signal on the run chart. The sponsor wants to roll it out anyway because 'the team believes in it'. What is the correct response?

Worth remembering

Which step of PDCA gets skipped, and why?

Check. By the time the change is in, everyone has moved on — and nobody decided in advance what checking would consist of.

What makes a PDCA prediction useful?

That it could turn out to be false. A number and a timescale can be checked; 'this should help' will be judged true by whoever proposed it.

Name three things a data collection plan must state beyond what to measure.

Who collects it, how often and for how long, and what else to record for stratification. The stratification field costs nothing at the time and cannot be reconstructed later.

Can you do this now?

Rate yourself honestly. We compare your rating with how you actually answered — the gap is more useful than either number alone.

  • I can run a PDCA cycle on a small change and state what I would measure at each step.

  • I can collect data against a written plan without changing how the work is done.

Your rating is recorded alongside your drill results. Neither alone marks the competency as met.