When an improvement process is initiated within an organization, it is important not only to carry out this process but also to evaluate and secure it. A practical way to approach this in a structured manner is with the A3 method. The Lean A3 method helps teams analyse problems, plan improvement actions, and document results.
What is the A3 method?
The A3 method is a technique from lean management. A3 lean owes its name to the A3 paper size, as the report is traditionally created on this format. The purpose of the A3 method is to analyse and solve complex problems in a clear and structured way. The A3 lean method does not only look at the symptoms of a problem but also digs deeper into the root causes. The document that emerges from the A3 methodology serves as a visual overview containing all relevant information – from problem analysis to action plan. The strength of A3 lean lies in its simplicity, clarity, focus on the core of the problem, and broad involvement, with multiple stakeholders contributing input. Since the A3 lean method supports the PDCA cycle, it contributes to continuous improvement within an organization.
How to create an A3 report
Lean A3 cannot exist without a report. The A3 report is all about structure. This structure consists of several steps and components, which we explain below:
- Problem description
Clearly and concretely describe which problem needs to be solved. Focus on facts and avoid vague descriptions to apply lean A3 effectively. - Current situation
Map out the current state. Use data, measurements, and observations to support your analysis, making the problem tangible. - Objective
Define measurable goals that should be achieved with the solution. These can include improvement percentages, time reduction, or quality enhancement. - Root cause analysis
Use tools such as the 5 Whys method or a fishbone diagram to get to the core of the problem. Only once the root cause has been identified can you move forward with the lean A3 method. - Improvement actions
Develop solutions that directly address the identified root causes. Ensure that actions are made concrete and clarify who is responsible for which actions and when they must be carried out. - Implementation plan
Create a plan that outlines all improvement actions along a timeline. Also, assign responsibilities for each action to specific individuals. - Results and evaluation
Measure whether the goals defined in step 3 have been achieved. Also discuss what went well during implementation and what could be improved further. - Sustainability (standardization)
Define how the improvement will become a permanent part of work processes to ensure sustainable results. Use standards or checklists to support this.
Example of A3 problem solving
To better illustrate the application of A3 problem solving, here is an example of A3 lean in a production environment.
Imagine: A factory notices that product waste on a packaging line is higher than normal. The problem is tackled using A3 problem solving. A lean A3 example would look like this on paper:
- Problem description: 12% of packaged products turn out to be damaged. This results in customer complaints.
- Current situation: A data analysis shows that most of the damage occurs at the transition to the sealing machine.
- Objective: Reduce waste from 12% to <3%. This should be achieved within 3 months.
- Root cause analysis: The 5 Whys reveal that the conveyor belt is incorrectly aligned, causing products to enter the machine at an angle.
- Improvement actions: Technicians realign the belt, and operators receive a checklist for daily maintenance.
- Implementation plan: Immediate realignment + operator training within 2 weeks.
- Results: After implementation, waste decreases to 2.5%.
- Sustainability (standardization): The checklist is included in the daily start-up routine.
A3 lean template
Want to work out your own A3 lean example? Then use an A3 lean template. Such an A3 lean template could look like this:
| Component | Content |
|---|---|
| Problem description | … |
| Current situation | … |
| Objective | … |
| Root cause analysis | … |
| Improvement actions | … |
| Implementation plan | … |
| Results | … |
| Sustainability | … |
Of course, you can also create your own lean A3 template tailored to your organization.
A3 method in the EZ-GO app
Creating and maintaining an A3 report often happens on paper or in separate documents. This can be unclear and makes collaboration difficult. With the EZ-GO app, this process becomes much simpler. For example, you can create and share digital lean A3s with your team. You can also maintain a visual overview, so everyone can quickly see the status at any time. Within EZ-GO, you can assign and visibly track actions and tasks for the A3 lean method among team members. Finally, securing results becomes easier as well, by integrating improvements into digital standards and checklists.
Questions about the A3 methodology? Contact us.
Would you like to learn more about the A3 lean method and how it can be applied in your organization? Or are you curious how the EZ-GO app can help accelerate and sustain improvement processes? Feel free to contact us. We would be happy to help.