How do you use the A3 report for lean manufacturing?

1 What is an A3 report?

An A3 report is a visual and concise way of communicating the key information of a lean project. The name originates from the size of the paper used, which is A3 or 11 x 17 inches. This report typically consists of eight sections, each with its own purpose and format. The background section provides the context and rationale, as well as details the current situation and problem to be solved. The current condition section shows data and facts that illustrate the problem, along with a root cause analysis to identify underlying causes. The goal section states the desired outcome and target performance, in relation to organizational goals and customer needs. Countermeasures list possible solutions and actions to address root causes and achieve the goal, with criteria for selecting the best option. The implementation plan details steps, responsibilities, resources, timeline, milestones, and deliverables for tracking progress. The follow-up plan defines measures and indicators to monitor effectiveness and sustainability of countermeasures. Results display actual outcomes and performance of the project, comparing them with goal and baseline, along with benefits and impacts on quality, cost, delivery, safety, morale. Lastly, reflection summarizes lessons learned and best practices from the project, as well as gaps and opportunities for further improvement.

2 Why use an A3 report?

An A3 report has several advantages for lean manufacturing, such as clarifying and communicating the problem and solution in a structured way, fostering a collaborative and cross-functional approach to problem-solving, supporting a data-driven decision-making process, and promoting learning and reflection from results. It also helps to align stakeholders on the same page, encourages input and feedback from different perspectives, avoids jumping to conclusions or relying on assumptions, and facilitates a continuous improvement culture.

3 How to use an A3 report?

Using an A3 report for lean manufacturing involves four main steps: planning, doing, checking, and acting. During the planning step, you define the problem, collect and analyze data, identify root causes, set a goal, and propose countermeasures. Tools such as fishbone diagrams, Pareto charts, 5 whys, and brainstorming are used to help in this step. Additionally, the first four sections of the A3 report are drafted and shared with team members and managers for approval. In the do step, countermeasures are implemented according to plan and schedule. Gantt charts, checklists, and standard work are used to help in this step. The fifth section of the A3 report is also updated and communicated regularly to team members and managers. During the check step, results are measured and evaluated using data and indicators from the follow-up plan. Control charts, histograms, and run charts are used to help in this step. The sixth and seventh sections of the A3 report are completed by comparing actual performance with the goal and baseline. Finally, during the act step, reflection is done to learn from the project and identify next steps for improvement. SWOT analysis, PDCA matrix, and gemba walks are used to help in this step. The eighth section of the A3 report is finalized before presenting it to team members and managers for recognition and feedback.

4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?