PDCA from Theory to Effective Applications: A Case Study of Design for Reducing Human Error in Assembly Process

This article describes an efficient and effective way to apply the PDCA (Plan-Do-Check-Act) method in the design process to meet quality and stakeholders' expectations. Through the case study of developing a smart workstation to train workers in the assembly process with a target to reduce the defects and improve the management task, the paper explores the main barriers and success factors for the PDCA cycle implemented in complex quality improvement projects. A prototype of the new workstation design is tested and shows significant benefits not only in defect reduction and management efficiency but also in newcomers' learning process. This research can be used as a benchmark application of PDCA in quality improvement and engineering design processes with systematic and comprehensible guidance of the cycle.