What is a process decision program chart?
The process decision program chart (PDPC) is a contingency planning tool from the seven management and planning tools. Plans usually describe what should happen; a PDPC asks what might happen instead. By looking at each activity in turn and listing what could go wrong, the team finds weak points early, while there is still time to prevent them or prepare a response. It is quick, visual and needs no ratings beyond a simple O or X.
How to build a PDPC
- Objective: the goal of the plan, at the root of the chart.
- Activities: the main steps needed to reach it (second level).
- What could go wrong: problems, delays and failures for each activity (third level).
- Countermeasures: preventive or contingent actions for each problem (fourth level).
- Feasibility: mark each countermeasure O (feasible) or X (not feasible), and add the feasible ones to the plan.
PDPC example
A site plans to go live with electronic batch records on a packaging line. The PDPC lists four activities: configuring templates, validating the system, installing tablets and network, and training operators. Validation could find critical defects late (high risk); an early supplier audit and testing of critical functions is feasible, while moving the go-live date is marked X. Wi-Fi coverage gaps at the end of the line are also rated high, but nobody has proposed a countermeasure yet, so the chart outlines that risk in red.
Related tools
- Tree diagram: break the objective into activities before adding risks.
- What-if analysis and FMEA: rated risk analyses for processes and designs.
- Action plan: track the countermeasures to completion.
How to use this Process Decision Program Chart tool
- State the objective. Click the dark box and write the goal of the plan.
- Add the activities. Click + next to the objective to add the main activities of the plan.
- Ask what could go wrong. For each activity, click + and describe each thing that could go wrong; rate it high, medium or low.
- Add countermeasures. For each problem, click + and describe what you will do, then mark it O (feasible) or X (not feasible) and give it an owner.
- Close the gaps. Risks without a feasible countermeasure are outlined in red; add one or accept the risk.
- Export. Export the chart and the risk table to PDF, PNG or Excel and add the countermeasures to the plan.
Frequently asked questions
What is a process decision program chart?
A process decision program chart (PDPC) is one of the seven management and planning tools. Starting from an objective and the activities of a plan, it asks for each activity "what could go wrong?" and then lists countermeasures for each problem, marking each countermeasure as feasible (O) or not feasible (X). The result is a plan with contingencies built in.
How do you make a PDPC?
Write the objective. Break the plan into its main activities (a tree diagram or the work breakdown helps). For each activity, brainstorm what could go wrong. For each problem, list countermeasures that prevent it or limit its effect, and decide whether each is feasible. Then build the feasible countermeasures into the plan.
What do O and X mean in a PDPC?
O (a circle) marks a countermeasure that is practical: it can be done in time, at acceptable cost, with the people available. X marks a countermeasure that is not feasible. Every important risk should have at least one O; the tool flags risks without one.
When should I use a PDPC?
Use it before implementing a plan that is new, complex, high-stakes or under time pressure: a product launch, a system go-live, a validation, a relocation. It is quicker than a full FMEA and focuses on the plan rather than the product.
What is the difference between a PDPC and an FMEA?
Both ask what could go wrong. A PDPC looks at the steps of a plan or project and produces contingencies, without numerical ratings. An FMEA analyses a product or process systematically with severity, occurrence and detection ratings. Use a PDPC for plans, FMEA for designs and processes.
How does a PDPC relate to a tree diagram?
A PDPC often starts from a tree diagram: the tree breaks the objective into activities, and the PDPC adds two more levels, what could go wrong and the countermeasures.