See and measure the loss
VSM, Gemba, OEE and Andon make the condition visible and establish the baseline.
CONTINUOUS IMPROVEMENT · QAPP
Turn an observed problem into an improvement that is demonstrated and sustained.
In QAPP, Continuous Improvement is not a list of tools. It is a controlled workflow: make the loss visible, define the problem, demonstrate the cause, implement the action, verify the result and update the standards or quality documents affected by the change.
AIAG CQI-20 · Effective Problem Solving Guide ↗AIAG CQI-8 · Layered Process Audit Guideline ↗AIAG Core Tools Overview ↗AIAG · Taking Effective Corrective Action: 8-D ↗
What CI means in QAPP
QAPP keeps the link between observation, data, cause, action and effectiveness. The method is selected from the real problem, not from a preferred acronym.
Define the problem
Scope the process, impact, current condition, target and owner.
Demonstrate the cause
A3, 8D/CQI-20, 5 Why, Ishikawa and data analysis support cause verification, not just brainstorming.
Test the countermeasure
PDCA and Kaizen connect the hypothesis to an experiment, result and deployment decision.
Hold the gain
Standard Work, 5S, LPA, Control Plan and process monitoring reduce regression to the previous condition.
What QAPP adds beyond the method
Baseline and target
Keep the starting condition and success criterion before implementing the action.
Ownership and deadlines
Every action has an owner, due date, status, escalation and history.
Evidence
Attach measurements, photos, approvals, checks and before/after results.
Effectiveness
Closure does not mean only “action completed”; QAPP can require effect verification after the defined period.
Feedback into Quality
If risk, control method or the process changes, CI can trigger review of PFMEA, Control Plan, MSA/SPC or change control.
Choose the method from the type of problem
| Problem type | Useful methods | Role |
|---|---|---|
| Flow, WIP, lead time | VSM · Kanban · Heijunka | Visualise flow, limit work in process and stabilise loading. |
| Equipment, stops, setup | OEE · TPM · SMED | Separate losses and address availability, speed or changeover. |
| Workplace and execution | 5S · Standard Work · Gemba · Andon | Define the normal condition and make deviations easy to see and escalate. |
| Problem solving | A3 · PDCA · 5 Why · Ishikawa · 8D/CQI-20 | Define, verify the causal mechanism, implement and demonstrate effectiveness. |
| Sustaining the result | Standard Work · LPA/CQI-8 · Control Plan · SPC | Turn the solution into a controlled rule and monitor whether the process remains stable. |
Continuous Improvement methods
Each page explains purpose, required data, practical steps, what QAPP can record, the Quality connection and the limits of the method.
Value Stream Mapping
Map material and information flow, waiting, inventory and bottlenecks.
Use it when: When lead time is high or the source of delay is unclear.
Open the detailed method →Standard Work
Define the current method, sequence, time and critical points for repeatable execution.
Use it when: When results depend too much on the person, shift or memory.
Open the detailed method →Pull & Kanban
Link replenishment to actual consumption using visual signals and WIP limits.
Use it when: When overproduction, excess inventory or shortages appear between processes.
Open the detailed method →Heijunka
Level volume and mix to reduce scheduling-driven variation.
Use it when: When workload varies heavily and creates queues or frequent changeovers.
Open the detailed method →TPM
Connect equipment losses to inspections, maintenance and clear ownership.
Use it when: When breakdowns, micro-stops or equipment defects dominate losses.
Open the detailed method →SMED
Reduce changeover time by separating internal and external work and simplifying remaining steps.
Use it when: When setup time limits flexibility, capacity or batch size.
Open the detailed method →OEE
Separate availability, performance and quality to locate capacity loss.
Use it when: When you need to identify which component reduces productive equipment use.
Open the detailed method →5S
Make workplace condition visible, repeatable and easy to verify.
Use it when: When disorder, searching, unstable conditions or missing standards affect the process.
Open the detailed method →Andon
Turn an abnormal condition into a signal with owner, response time and escalation.
Use it when: When problems are seen but response is slow or unclear.
Open the detailed method →Gemba Walk
Structure direct observation of the process and separate facts from assumptions.
Use it when: When the team discusses a problem without observing the actual working condition.
Open the detailed method →Kaizen
Turn small opportunities into controlled experiments with baseline, action and result.
Use it when: When local improvements can be tested quickly and standardised.
Open the detailed method →A3 Problem Solving
Connect the problem, current condition, cause, countermeasures and follow-up in one logical thread.
Use it when: When structured problem solving and visual communication are needed in one record.
Open the detailed method →PDCA
Plan the change, test it, verify the result and standardise or adjust.
Use it when: When a solution needs validation before wider deployment.
Open the detailed method →5 Why
Explore the causal chain and require evidence for each important link.
Use it when: When the immediate cause is known but the underlying mechanism must be demonstrated.
Open the detailed method →Ishikawa / Fishbone
Organise cause hypotheses into categories and turn them into a verification plan.
Use it when: When many potential causes exist and the team needs structure before testing.
Open the detailed method →How CI connects to AIAG
AIAG CQI-20 describes a robust problem-solving process focused on better problem descriptions, team participation, analysis, prioritisation, progress checks and avoiding skipped steps. QAPP uses this logic to preserve the thread from problem to cause, action and verification.
AIAG CQI-8 connects Layered Process Audits with KPIs, ownership, management review and effectiveness measurement. QAPP uses LPA as a sustainment and feedback mechanism, not as a simple checklist.
AIAG describes the Core Tools as interconnected tools supporting quality from planning through production and continuous improvement. This is why a CI finding can feed back into PFMEA, Control Plan, MSA, SPC, APQP or PPAP when a change affects risk, control or process approval.
QAPP presents VSM, 5S, Kanban, Heijunka, TPM, SMED, OEE, Andon, Gemba, Kaizen, A3 and PDCA as CI/support methods. They are not labelled as AIAG Core Tools unless an explicit AIAG reference exists. QAPP does not reproduce AIAG manuals and does not automatically certify compliance.