Download - Process Analysis 102
![Page 1: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/1.jpg)
Process Analysis 102
Quality: The Basic Tool Kit
![Page 2: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/2.jpg)
Process Analysis Tools
4 Tools in your Quality Tool Kit1. F2. F3. M4. S
![Page 3: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/3.jpg)
Process Analysis Tools
4 Tools in your Quality Tool Kit1. Flowchart2. F3. M4. S
![Page 4: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/4.jpg)
![Page 5: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/5.jpg)
Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help:1. Flowchart: a picture of the separate steps of a
process in sequential order2. Failure modes and effects analysis: a step-by-
step approach for identifying all possible design failures
3. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error.
4. Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
![Page 6: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/6.jpg)
![Page 7: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/7.jpg)
Process Analysis Tools
4 Tools in your Quality Tool Kit1. Flowchart2. Failure Modes and Effects Analysis3. M4. S
![Page 8: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/8.jpg)
![Page 9: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/9.jpg)
Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help:1. Flowchart: a picture of the separate steps of a
process in sequential order.2. Failure modes and effects analysis: a step-by-
step approach for identifying all possible failures in a design, a manufacturing or assembly process
3. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error.
4. Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
![Page 10: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/10.jpg)
![Page 11: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/11.jpg)
Process Analysis Tools
4 Tools in your Quality Tool Kit1. Flowchart2. Failure Modes and Effects Analysis3. Mistake Proofing4. S
![Page 12: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/12.jpg)
![Page 13: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/13.jpg)
Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help:1. Flowchart: a picture of the separate steps of a
process in sequential order.2. Failure modes and effects analysis: a step-by-
step approach for identifying all possible design failures
3. Mistake proofing: the use of any automatic device or method that makes it impossible for an error
4. Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
![Page 14: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/14.jpg)
![Page 15: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/15.jpg)
Process Analysis Tools
4 Tools in your Quality Tool Kit1. Flowchart2. Failure Modes and Effects Analysis3. Mistake Proofing4. Spaghetti Diagram
![Page 16: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/16.jpg)
![Page 17: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/17.jpg)
Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help:1. Flowchart: a picture of the separate steps of a
process in sequential order.2. Failure modes and effects analysis: a step-by-
step approach for identifying all possible design failures
3. Mistake-proofing: the use of any automatic device or method that makes it impossible for an error.
4. Spaghetti diagram: a visual representation using a continuous flow line tracing the process path
![Page 18: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/18.jpg)
![Page 19: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/19.jpg)
Flowchart
Elements that may be included:sequence of actionsmaterials or services entering or leaving the
process (inputs and outputs)decisions that must be madepeople who become involvedtime involved at each stepprocess measurements
Process flowchartProcess flow diagram
![Page 20: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/20.jpg)
![Page 21: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/21.jpg)
![Page 22: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/22.jpg)
FlowchartFlow charts are simple diagrams
To draw a flowchart: brainstorm the tasks and decisions
Then map these out in flow chart format
Finally, challenge your flow chart
![Page 23: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/23.jpg)
Failure Modes and Effects Analysis
FMEAA step-by-step approach for identifying all
possible failuresDesign, manufacturing or assembly process or
product or service
Failure modes = what could go wrongEffects analysis = how would it happen, how
likely is it to go wrong and how bad would it be?
FMEAHouse of Quality
![Page 24: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/24.jpg)
What is FMEA?
1. What can go wrong?
2. What can be done to keep that from happening?
![Page 25: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/25.jpg)
Why do FMEA?1. When preventing problems is cheaper and easier than
cleaning them up2. Some things are too risky or costly to incur mistakes
![Page 26: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/26.jpg)
When to do FMEA?1. Before there’s a problem2. During a project’s lifespan
3. After there’s a problem, so it doesn’t happen again
![Page 27: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/27.jpg)
Failure modes and effects analysis
How to do FMEA1. Gather your smart people together2. Represent every area where a problem could
occur3. Use a worksheet to record the information
![Page 28: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/28.jpg)
Mistake-proofing
The use of any automatic device or method that either makes it impossible for an error to occur or makes the error immediately obvious once it has occurred.
Poka-yokeFail safe
![Page 29: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/29.jpg)
1. Eliminate the process step2. Replace the step
3. Facilitate the correct action4. If not, make detection easy
![Page 30: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/30.jpg)
When to do mistake proofing?1. Where human error exists 2. At a handoff
3. When an error is costly
![Page 31: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/31.jpg)
1. Self inspection 2. Source inspection 3. At the next step
![Page 32: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/32.jpg)
Mistake-proofingElimination
seeks to eliminate the possibility of errorReplacement
substitutes a more reliable processPrevention
engineers the product or processFacilitation
makes work easier to performDetection
involves identifying an errorMitigation
seeks to minimize the effects of errors
![Page 33: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/33.jpg)
Spaghetti Diagram
A spaghetti diagram is a visual representation using a continuous flow line tracing the path of an item or activity through a process.
Layout diagram
The continuous flow line enables process teams to identify redundancies in the work flow and opportunities to expedite process flow.
![Page 34: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/34.jpg)
![Page 35: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/35.jpg)
![Page 36: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/36.jpg)
![Page 37: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/37.jpg)
Process Analysis ToolsPA Tool Definition
Flowchart: a picture of the separate steps of a process in sequential order.
Failure modes and effects analysis:
a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service.
Mistake-proofing: the use of any automatic device or method that makes it impossible for an error to occur.
Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
![Page 38: Process Analysis 102](https://reader036.vdocuments.us/reader036/viewer/2022062323/56816348550346895dd3d706/html5/thumbnails/38.jpg)
Process Analysis 102
Quality: The Basic Tool Kit
Allen K. Pratt, MBA, CIRMHawkeye Consulting Advisors, Ltd.www.HawkeyeConsultingAdvisors.com