Download - Buspro infosheet6
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Process Analysis
“If you cannot describe what you are doing as aprocess, you do not know what you are doing.”
W.E. Deming
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What is a process?
A process is a series of independent tasks that transforms an input into output material of higher value for
the organization
Examples:
1. Honda transforms steel, rubber, and plastic into cars
2. McDonald’s transforms meat, potatoes, and sauces into packaged food
3. Dell transforms customer orders into PC’s
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Process Analysis
Why do we need to analyze the process?- To identify inefficient tasks- To spot possible effectiveness
improvement tasks- To understand where value can be added
How can we analyze a process? Map it!What are the relevant performance measures?
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• What is its capacity? How many units per unit time go through each task? The process as a whole?
• What is the bottleneck? Which production step limits the process capacity?
• What is the throughput time? How long does it take to get through the system?
Process Analysis: the performance measures
Assume a process is in place. What do we need to measure in order to understand how efficient it is?
Task 1 Task 2 Task 3
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How do we measure capacity?
Cycle Time: Average time for completion of a unit at a production step or process. Does not include waiting. Measured as time/unit
Throughput Rate: Average number of units processed over a time interval. Measured as units/time
1
Cycle TimeThroughput rate =
Key relationship
Capacity of a task is the physical limitation in terms of “how much can be processed at this task”
Capacity = throughput rate
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Computing Cycle Times
Processing a fixed amount of work
Cycle Time = Set-up Time + (Batch size) x (Time per unit)
Batch size
Example: Producing 100 cars. On average, production takes 5 hours per car. It takes 50 hours to set up the production line.
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Computing Cycle Times
Setup time:15 min
A B
Question: What is the cycle time between points A and B of the process, if we work in batches of 10?
Production Time:25min/unit
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What is a bottleneck?
Which task is the bottleneck?
3 units/hr 5 units/hr 2 units/hr
Bottleneck is theprocess stage with thesmallest throughput
rate (longest cycle time)
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Capacity of a process
The capacity of the process is:
minimum throughput rate at any of the stages
What is the capacity of this process?
3 units/hr 5 units/hr 2 units/hr
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How do we measure throughput time?
Throughput Time: Average time that a unit takes to go through the entire process (including waiting
time). Measured as time
Work in Process(WIP): Average number of units in system over a time interval. Measured as units
WIP
Throughput rateThroughput time =
Key relationship
(Little’s Law)
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3 Stages to Flow Improvement
1 - See the current state
2 - Analysis
3 - Take action to apply flow improvement principles
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Stage 1- Current State Flow Analysis Tool: 4 elements
•Process steps•Communication steps•Responsible clinically•Responsible for each part of the process
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Add value
Remove waste
Stage 2 Analysis - Understanding your Map
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Activity:
Review the completed current state map and identify the value and non-value added steps
Compare the value and non-value steps identified on the completed current state map
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•Waiting•Mistakes•Uncoordinated activity•Stock•Transportation•Motion• Inappropriate processing
Opportunities to Remove Waste
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On the flow analysis map identify waste and plot the different sorts of waste
Activity:
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Analysis Summary
StepsTotal number StepsNumber of value stepsValue steps as % total
stepsTimeTotal time Hrs:MinsTime of value stepsValue Time as % total
time
Waste• Waiting• Mistakes• Uncoordinated activity• Stock• Transportation• Motion• Inappropriate processing
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Waiting is the most important of all the wastes because:
▲The process STOPS▲Inhibits FLOW▲Does not add value for the PATIENT
Waiting
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Stage 3: Take action to
apply flow improvement
principles
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4 characteristics of smooth flow
1 Small batch sizes2 Linked processes3 Setting the pace4 Overall co-ordination
Next - helping the value adding steps flow