Comments on: Toyota A3 Report Example [video]

By: Carlos Scholz

Carlos Scholz — Thu, 11 Aug 2011 21:28:11 +0000

Pete,
the video is missing a key ingredient: Gap / Root Cause Analysis. You can’t jump from target state to action plan without knowing your root causes, even if it’s only a Proposal A3. That’s my point of view at least.

By: Carlos Scholz

Carlos Scholz — Thu, 11 Aug 2011 21:23:42 +0000

Hi Pete,

Pretty good article, you cover the basics of the A3 concept as a problem solving methodology that has to be followed rigorously (although A3 can also be used for other things, not only Problem Solving).
One thing about the video though, is that it’s missing a key ingredient of A3, which is the Gap/Root Cause Analisys. You can’t go from Target State to Action Plan, even if this is a Proposal A3… that’s my point of view at least.

By: Pete Abilla

Pete Abilla — Tue, 24 May 2011 03:40:06 +0000

Thanks for your comment, Brian.

By: Pete Abilla

Pete Abilla — Tue, 24 May 2011 03:34:02 +0000

In reply to Pele de Brasil.

Pele,

Yes, you’re right. The important thing with the A3 is that it is rigorously followed and that it becomes a means of communication as well as a vehicle for learning (and communicating). Thanks much.

Pete

By: Pete Abilla

Pete Abilla — Tue, 24 May 2011 03:31:15 +0000

In reply to Raj.

Hi Raj,

The A3 is both a method and a means of communication. The actual paper size of 11×17 is really not that important. What is important is that the A3 process is followed – a teacher with a student – and that each of the steps is rigorously followed. Reporting the results at the end – that actual 11×17 printout is the very last thing you should worry about. The ability to see all the information and approach on 1 sheet of paper is very beneficial, but where it’s not feasible, then adjust.

Thanks for reading shmula.

By: Raj

Raj — Tue, 24 May 2011 03:27:08 +0000

A3 is great for lean and makes lean training easier to do. But, in some countries (like India for me), printing on an 11×17 size paper is not practical. Any advice on how to do A3 without having to print such big paper?

By: Pele de Brasil

Pele de Brasil — Tue, 24 May 2011 03:20:15 +0000

In Brasil my home town, there are many practitioners of Lean Manufacturing. I have worked in 3 different factories and I saw Lean process in each one, but they were done differently but the same. In some, A3 was used. In others, just Kaizen newspapers. But same output.

By: Dulce

Dulce — Tue, 24 May 2011 03:15:53 +0000

This is excellent. You explain the Toyota problem solving process in a simple way. Great work and excellent site on Lean Training and Lean Manufacturing!

By: Mark

Mark — Wed, 22 Jul 2009 14:25:29 +0000

Great article!

I’ve seen 5-Why’s and Fishbone diagrams used before but never heard about the rest of the A3 process.

I definitely like the “Understand the Current Process” portion of the process but I still believe the root cause analysis portion (5-Whys of Fishbone Diagrams) is fatally flawed. For a discussion of the reasons why, see:

[link redacted by site owner]

Thanks again for the great article.

Mark

By: mark

mark — Thu, 06 Mar 2008 14:49:01 +0000

[link redacted by site owner] there is 2 downloads one is a word doc. hope this helps.

By: Linda M

Linda M — Fri, 01 Feb 2008 20:46:54 +0000

Hello – I would like the A-3 form in a Word document so we can use it as a template. Where could I find that…not a pdf or .xls

By: james

james — Wed, 14 Mar 2007 17:09:02 +0000

Good stuff. I still have an A3 from our tour of the parts distribution center and often refer to it.

By: Mark Graban

Mark Graban — Tue, 13 Mar 2007 19:57:22 +0000

On my blog, I posted a link to the recent WSJ article that showed Toyota showing the LAPD to use an A3 report.

There was no copyright on the A3 ppt that they had for download, so here is the direct link…

By: robert thompson

robert thompson — Tue, 13 Mar 2007 16:19:19 +0000

A nice summary of the A3 approach. I think that the A3 approach offers a structure to view a problem through the eyes of the customer and forces an understanding the current condition before jumping to a solution. I discuss how the A3 approach can be integrated with the DMAIC framework on my blog.

Rob