Tool 146: Process Analysis

AKA

N/A

Classification

Analyzing/Trending (AT)

Tool description

The process analysis technique helps to trace the source of variation and is, therefore, a useful method to identify root causes of a problem. Process analysis is typically performed using an activity-level process flowchart and by asking a series of questions to explore or justify excessive cycle time, approvals, improper sequence, delays, and other process deficiencies.

Typical application

• To review, analyze, and improve an existing process.

• To identify process improvement opportunities.

• To fine-tune processes in an organizational change project.

Problem-solving phase

→	Select and define problem or opportunity
→	Identify and analyze causes or potential change
→	Develop and plan possible solutions or change
	Implement and evaluate solution or change
	Measure and report solution or change results
	Recognize and reward team efforts

Typically used by

	Research/statistics
	Creativity/innovation
	Engineering
	Project management
2	Manufacturing
	Marketing/sales
4	Administration/documentation
3	Servicing/support
	Customer/quality metrics
1	Change management

links to other tools

before

• Symbolic Flowchart

• Organization Chart

• Process Mapping

• Process Flowchart

• Cycle Time Flowchart

after

• Activity analysis

• Variance Analysis

• Work Flow Analysis (WFA)

• Facility Layout Diagram

• Decision Process Flowchart

Notes and key points

• To constuct a process flow, several tools are available:

  • process flowchart

  • symbolic flowchart

  • Process Mapping

  • cycle time flowchart

  • activity analysis

    Using any one of these will allow a process improvement team to achieve established team goals.

• The given list of 10 process analysis questions is optional. The number and content of questions may change in accordance with the complexity of any given process.

Step-by-step procedure

• STEP 1 As a prerequisite activity, a facilitated team develops a process flowchart at the activity-level for the process selected.

• STEP 2 A set of standard process analysis questions is displayed by the facilitator. The team reviews the questions, adds, deletes, or revises questions to fully cover the process to be analyzed.

• STEP 3 Using the finalized list of questions, the team discusses all activities in the process and provides responses to the questions.

• STEP 4 Finally, the facilitator asks participants to recheck all responses, makes final revisions, and dates the list.

• STEP 5 The information serves as an input to a variance analysis process, a logical next step for the team.

Example of tool application

Typical Process Analysis Questions

Date: xx/xx/xx

Are the connected tasks performed in a logical sequence? No, materials check should have been done earlier Does the defined process show more than two loopbacks? Yes Do individual tasks have relatively long cycle times? No Does every task add value to the process? No, audio-visual check does not add value to this process. Are there redundant tasks? No Does the process reflect excessive delays? No Does the process contain sources of key variance? No Are there more than two approval requirements? No Can the process flow be changed to reduce tasks? Yes, remove materials and A/V checks Does this process have a high level of consistency? Yes