Process Analysis Tools 4 Tools in your Quality Tool Kit F F M S Process Analysis Tools 4 Tools in your Quality Tool Kit Flowchart F M S Process Analysis Tools When you want to understand a work process or some part of a process these tools can help ID: 798436
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Process Analysis 102
Quality: The Basic Tool Kit
Slide2Process Analysis Tools
4 Tools in your Quality Tool KitFFMS
Slide3Process Analysis Tools
4 Tools in your Quality Tool KitFlowchartFMS
Slide4Slide5Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help:Flowchart: a picture of the separate steps of a process in sequential orderFailure modes and effects analysis: a step-by-step approach for identifying all possible design failures
Mistake-proofing
: the use of any automatic device or method that
makes it impossible for an error.
Spaghetti diagram: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
Slide6Slide7Process Analysis Tools
4 Tools in your Quality Tool KitFlowchartFailure Modes and Effects AnalysisMS
Slide8Slide9Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help: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 processMistake-proofing:
the use of any automatic device or method that makes
it impossible for an error.Spaghetti diagram
: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
Slide10Slide11Process Analysis Tools
4 Tools in your Quality Tool KitFlowchartFailure Modes and Effects AnalysisMistake ProofingS
Slide12Slide13Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help: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 design failuresMistake proofing: the use of any automatic device or method that
makes it impossible for an errorSpaghetti diagram
: a visual representation using a continuous flow line tracing the path of an item or activity through a process.
Slide14Slide15Process Analysis Tools
4 Tools in your Quality Tool KitFlowchartFailure Modes and Effects AnalysisMistake ProofingSpaghetti Diagram
Slide16Slide17Process Analysis Tools
When you want to understand a work process or some part of a process, these tools can help: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 design failuresMistake-proofing
: the use of any automatic device or method that makes
it impossible for an error.Spaghetti diagram: a visual representation using a continuous flow line tracing the process path
Slide18Slide19Flowchart
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 measurementsProcess flowchartProcess flow diagram
Slide20Slide21Slide22Flowchart
Flow charts are simple diagramsTo draw a flowchart: brainstorm the tasks and decisions Then map these out in flow chart formatFinally, challenge your flow chart
Slide23Failure Modes and Effects Analysis
FMEAA step-by-step approach for identifying all possible failuresDesign, manufacturing or assembly process or product or serviceFailure 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
Slide24What is FMEA?
What can go wrong?What can be done to keep that from happening?
Slide25Why do FMEA?
When preventing problems is cheaper and easier than cleaning them upSome things are too risky or costly to incur mistakes
Slide26When to do FMEA?
Before there’s a problemDuring a project’s lifespanAfter there’s a problem, so it doesn’t happen again
Slide27Failure modes and effects analysis
How to do FMEAGather your smart people togetherRepresent every area where a problem could occurUse a worksheet to record the information
Slide28Mistake-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
Slide29Eliminate the process step
Replace the stepFacilitate the correct actionIf not, make detection easy
Slide30When to do mistake proofing?
1. Where human error exists 2. At a handoff 3. When an error is costly
Slide311. Self inspection 2. Source inspection 3. At the next step
Slide32Mistake-proofing
Eliminationseeks to eliminate the possibility of errorReplacementsubstitutes a more reliable processPreventionengineers the product or processFacilitationmakes work easier to performDetection
involves identifying an errorMitigation
seeks to minimize the effects of errors
Slide33Spaghetti 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 diagramThe continuous flow line enables process teams to identify redundancies in the work flow and opportunities to expedite process flow.
Slide34Slide35Slide36Slide37Process Analysis Tools
PA ToolDefinitionFlowchart:
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.
Slide38Process Analysis 102
Quality: The Basic Tool Kit
Allen K. Pratt, MBA, CIRM
Hawkeye Consulting Advisors, Ltd.
www.HawkeyeConsultingAdvisors.com