Tool 221: Work Flow Analysis (WFA)


AKA

Link Analysis, Assembly Flow

Classification

Changing/Implementing (CI)

Tool description

The construction of a work flow analysis (WFA) diagram is absolutely necessary to show how work actually (physically) flows from person to person, via groups and departments throughout the organization. Once completed, the work flow diagram will illustrate process flows, methods, information, and material movement.

Work flow analysis is often used as a problem-solving tool to identify process loops, cross-over, redundant moves, bottlenecks, and other inefficient or non-valueadding activities. It is of great assistance in understanding the existing process before improvements can be proposed in process redesign or reengineering efforts.

Typical application

  • To show the sequential steps involved in moving people, material, documentation, or information in a process.

  • To diagram or baseline work movement in order for a team to understand the current work-flow sequence.

  • To illustrate a system's inefficiency.

  • To identify and eliminate illogical process flows.

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

3

Creativity/innovation

Engineering

4

Project management

2

Manufacturing

Marketing/sales

5

Administration/documentation

Servicing/support

Customer/quality metrics

1

Change management

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links to other tools

before

  • Facility Layout Diagram

  • Fault Tree Analysis (FTA)

  • Symbolic Flowchart

  • Gozinto Chart

  • Cycle Time Flowchart

after

  • Process Analysis

  • Failure Mode Effect Analysis (FMEA)

  • Action Plan

  • Decision Process Flowchart

  • Consensus Decision Making

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Notes and key points

The sequence of flow can be shown as numbering sections of the flow path as shown . Other process paths can be encoded as or .

Step-by-step procedure

  • STEP 1 The team identifies functions and responsibilities of the work-flow process to be analyzed. See example Picture Frame Assembly.

  • STEP 2 The second step is to obtain a current floor plan and to "walk" the flow of the selected process. Mark up the floor plan displaying the basic "as is" flow. For repeats or different process phases, use different color markers. Timing the process at various stages will provide additional data: the cycle times of tasks, movements, and delays. The resulting diagram is sometimes referred to as a "spaghetti diagram" because of the multiline crossover appearance.

  • STEP 3 The team then performs an analysis of the current process and recommends a first draft of equipment rearrangements and work flow changes to reduce or eliminate process steps.

  • STEP 4 Step four requires team consensus to be reached and a presentation given to process owners and other interested parties.

  • STEP 5 Date the completed work flow analysis diagram.

Example of tool application

click to expand




Six Sigma Tool Navigator(c) The Master Guide for Teams
Six Sigma Tool Navigator: The Master Guide for Teams
ISBN: 1563272954
EAN: 2147483647
Year: 2005
Pages: 326

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